US9962155B2 - Apparatus and method for minimally invasive suturing - Google Patents

Abstract

An apparatus and method for minimally invasive suturing is disclosed. A suturing device for minimally invasive suturing includes proximal section having a proximal end, a distal end, and a longitudinal axis therebetween, a suture head assembly extending from the distal end of the proximal section; a suturing needle having a pointed end and a blunt end, the suturing needle capable of rotating about an axis approximately perpendicular to a longitudinal axis of the proximal section, wherein the pointed end of the suturing needle is positioned within the suture head assembly prior to and after rotation of the suturing needle, and an actuator extending from the proximal end of the proximal section to actuate a reciprocating needle drive having a needle driver for engaging and rotating the suturing needle.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/480,561, filed Apr. 6, 2017, now U.S. Pat. No. 9,795,376, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/357,375, filed Nov. 21, 2016, now U.S. Pat. No. 9,700,301, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/265,650, filed Sep. 14, 2016, now U.S. Pat. No. 9,597,071, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/796,642, filed Jul. 10, 2015, now U.S. Pat. No. 9,474,523, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/472,090, filed Aug. 28, 2014, now U.S. Pat. No. 9,451,948, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 13/361,444 filed Jan. 30, 2012, now U.S. Pat. No. 8,821,519, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 12/592,174, filed on Nov. 20, 2009, now U.S. Pat. No. 8,123,764, which is a continuation-in-part of and claims the benefit of priority to U.S. patent application Ser. No. 11/231,135, filed Sep. 20, 2005, now U.S. Pat. No. 7,862,572, which in turn claims the benefit of priority to U.S. Provisional Application Ser. No. 60/611,362, filed Sep. 20, 2004.

This patent application is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/480,561, filed Apr. 6, 2017, now U.S. Pat. No. 9,795,376, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/357,375, filed Nov. 21, 2016, now U.S. Pat. No. 9,700,301, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/265,650, filed Sep. 14, 2016, now U.S. Pat. No. 9,597,071, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/796,642, filed Jul. 10, 2015, now U.S. Pat. No. 9,474,523, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/472,090, filed Aug. 28, 2014, now U.S. Pat. No. 9,451,948, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 13/361,444 filed Jan. 30, 2012, now U.S. Pat. No. 8,821,519, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 12/592,174, filed on Nov. 20, 2009, now U.S. Pat. No. 8,123,764, which is a continuation-in-part of and claims the benefit of priority to International Application No. PCT/US2008/06674 filed May 23, 2008, which in turn claims the benefit of priority to U.S. Provisional Application Ser. No. 60/939,887, filed May 24, 2007.

This Application is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/480,561, filed Apr. 6, 2017, now U.S. Pat. No. 9,795,376, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/357,375, filed Nov. 21, 2016, now U.S. Pat. No. 9,700,301, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/265,650, filed Sep. 14, 2016, now U.S. Pat. No. 9,597,071, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/796,642, filed Jul. 10, 2015, now U.S. Pat. No. 9,474,523, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/472,090, filed Aug. 28, 2014, now U.S. Pat. No. 9,451,948, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 13/361,444 filed Jan. 30, 2012, now U.S. Pat. No. 8,821,519, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 12/592,174, filed on Nov. 20, 2009, now U.S. Pat. No. 8,123,764, which is a continuation-in-part of and claims the benefit of priority to U.S. patent application Ser. No. 12/175,442, filed Jul. 17, 2008, now U.S. Pat. No. 7,976,555.

This patent application is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/480,561, filed Apr. 6, 2017, now U.S. Pat. No. 9,795,376, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/357,375, filed Nov. 21, 2016, now U.S. Pat. No. 9,700,301, which in turn is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 15/265,650, filed Sep. 14, 2016, now U.S. Pat. No. 9,597,071, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/796,642, filed Jul. 10, 2015, now U.S. Pat. No. 9,474,523, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 14/472,090, filed Aug. 28, 2014, now U.S. Pat. No. 9,451,948, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 13/361,444 filed Jan. 30, 2012, now U.S. Pat. No. 8,821,519, which is a continuation of and claims the benefit of priority to U.S. patent application Ser. No. 12/592,174, filed on Nov. 20, 2009, now U.S. Pat. No. 8,123,764, which claims the benefit of priority to U.S. Provisional Application Ser. No. 61/200,180, filed Nov. 25, 2008.

Each of the aforementioned patent applications is incorporated by reference herein in its entirety for any purpose whatsoever.

FIELD

The embodiments disclosed herein relate to a medical device for suturing tissue, and more particularly to a device for the manipulation and control of a suturing needle during minimally invasive suturing, methods for making such a device and methods for using such a device for suturing tissue.

BACKGROUND

Minimally invasive surgery (MIS) has allowed physicians to carry out many surgical procedures with less pain and disability than conventional, open surgery. Unlike conventional open surgery, where the surgical site is readily accessible through a large incision, enabling the surgeon to easily visualize and manipulate both tissue and instruments, MIS requires the surgeon to operate remotely by inserting and manipulating instruments through small punctures (“keyhole surgery”) or through natural orifices, including for example the vagina, the esophagus, or the anus.

In MIS, a small puncture is typically made in the body. Medical instruments are then inserted through a cannula. A cannula has a small inside diameter, typically 5-10 millimeters (mm), and sometimes up to 20 millimeters (mm) or more. A number of such cannulas may be inserted into the body for any given operation. Minimally invasive surgical instruments are necessarily smaller, and are also generally longer and therefore are more difficult to manipulate with precision.

Perhaps the most problematic surgical task in MIS is suturing. Suturing requires coordinated manipulation with both hands of small needles and sutures that are difficult to visualize (particularly when only indirect, two-dimensional video imaging is available) as well as the several instruments (including needle-drivers and pick-up forceps) ordinarily used to suture by hand. In an environment characterized by limited space, limited visualization, and limited mobility, many surgeons find minimally invasive suturing by hand an extremely difficult, often virtually impossible, surgical task.

In the preferred method of suturing by hand, a grasping forceps (“needle driver”) is held by the surgeon and is used to grip a curved needle near the needle's tail. Pronation of the surgeon's wrist drives the needle into the tissue. When the point of the curved needle emerges from the tissue, the surgeon releases the needle from the grip of the needle driver and grasps the point with another forceps (“pick-ups”). The surgeon then pulls the curved needle by the needle point, preferably in a circular path following the arc of the needle's curvature to follow the most atraumatic path through the tissue, until the entire length of the needle has exited the tissue. Each time a stitch is placed, the curved needle is thus driven around in a complete circular arc. Individual (interrupted) stitches are placed by tying off the suture following placement of each stitch. Running (continuous) stitches are placed by repeatedly driving the curved needle in a complete circular arc repeatedly until the desired length of suture and number of stitches has been placed. In order to place additional interrupted or continuous stitches, the surgeon must let go of the point of the needle and re-grasp the needle near the needle's tail.

In the manual suturing technique described above, the direct handling of the needle can result in accidental needle pricks through a surgeon or nurse's gloves, posing a potential risk of infection for the surgeon, nurse, staff, and patient, or cause the needle to become contaminated with pathogenic bacteria that can cause onset of infection at the site of the sutures. There is also a risk of the needle penetrating internal organs or vessels and causing a serious, and often fatal infection.

Various devices for suturing for MIS are described in U.S. Pat. No. 5,643,295 entitled “Methods and Apparatus for Suturing Tissue”; U.S. Pat. No. 5,665,096 entitled “Needle Driving Apparatus and Methods of Suturing Tissue”; U.S. Pat. No. 5,665,109 entitled “Methods and Apparatus for Suturing Tissue”; U.S. Pat. No. 5,759,188 entitled “Suturing Instrument with Rotatably Mounted Needle Driver and Catcher”; U.S. Pat. No. 5,860,992 entitled “Endoscopic Suturing Devices and Methods”; U.S. Pat. No. 5,954,733 entitled “Suturing Instrument with Rotatably Mounted Needle Driver and Catcher”; U.S. Pat. No. 6,719,763 entitled “Endoscopic Suturing Device”; and U.S. Pat. No. 6,755,843 entitled “Endoscopic Suturing Device”, all of which are incorporated by reference in their entireties for the teachings therein.

Assignees' U.S. Pat. No. 5,437,681, U.S. Pat. No. 5,540,705 and U.S. Pat. No. 6,923,819 disclose a suturing device with thread management comprising a protective cartridge, suturing needle and needle rotation drive, the disclosures of which are hereby incorporated by reference. The devices described in the above-mentioned patents and patent application comprise a mechanism for driving a protected needle however, the needle is rotated about an axis that is parallel to the axis of the device. In addition, the orientation and size of the suturing device makes it difficult to visualize and cumbersome to use for MIS.

Therefore, there remains a need in the art for a minimally invasive suturing device that is easily manipulated within the small diameter of the cannula; functions in an environment characterized by limited space, limited visualization, and limited mobility; mimics the preferred method of suturing used by surgeons; permits the surgeon to secure and tie knots quickly and with controlled tension; places continuous stitches; and protects user's from accidental needle sticks during needle handling, as well as internal organs and vessels, from inadvertent needle-pricks.

SUMMARY

Devices and methods for minimally invasive suturing of tissue internal to a body are disclosed herein.

According to aspects illustrated herein, there is provided a medical device for closing openings internal to a patient's body, which closely emulates or replicates the manual suturing actions carried out by a surgeon. The device offers several advantages over conventional methods used by surgeons for suturing tissue during minimally invasive surgery in that the device provides a hand-held suturing instrument of relatively simple mechanical construction that requires no external motive source. The presently disclosed embodiments provide relative ease of operation for the surgeon with only one hand.

According to aspects illustrated herein, a suture head assembly may be removably attached to an actuator mechanism of the suturing device. The diameter of the device is small enough to fit into a typical cannula, thus making the device extremely easy to maneuver, as well as suture, during endoscopic or other MIS procedures. Also, the suture head assembly of the device can be laterally articulated to the left of center, to the right of center, up, and down, once inside the cannula, which is ideal for use in the course of endoscopic surgery, including laparoscopy, thoracoscopy and arthroscopy, as well as other less-invasive surgical procedures.

The device of the present disclosed embodiments closely emulates or replicates the manual suturing actions carried out by a surgeon. For example, during manual suturing by hand, the needle is held in forceps and travels in a circular arc with no obstructions anywhere in the interior of the arc. The design of the suturing device of the present disclosed embodiments allows for a lack of obstruction in the center of the arc of the needle during suturing. In other words, there is no hub at the center of the circular arc of the suturing needle. The entire area within the circular arc of the needle is unobstructed. This allows for the user to have better visualization during operation, unlike the present mechanical suturing methods, while maintaining control over needle movement.

In accordance with one embodiment a “locomotive-type” drive mechanism is provided for advancing the needle about a path of travel. This embodiment of a drive enables the small diameter of the device and affords better visualization during operation because of the lack of a hub. There are many benefits afforded by the design of the suturing device of the presently disclosed embodiments, including, but not limited to, more tissue being able to fit into the device, thus enabling a bigger bite of tissue and a more secure suture; the device can be used to ligate, that is, place a loop of suture around a blood vessel, duct, or other tubular structure; and the device can be inserted further into smaller incisions/openings (one side of the aperture can be inserted deeply, for example).

A benefit provided by the suturing device of the presently disclosed embodiments is that the device enables maneuvering a suturing material through a tissue incision in a manner substantially similar to the way a surgeon would do so by hand. In particular, the suturing device first pushes a suturing needle from the tail of the needle and drives the point of the needle through the tissue. The device then picks up the point of the needle that passed through the tissue, and pulls the remainder of the suturing needle and the suture attached to the suturing needle through the tissue. The suturing needle thus consistently follows the arc of the needle's own curve, which is the preferred method of suturing, in the most atraumatic way of passing a needle through tissue. A benefit provided by the suturing device of the presently disclosed embodiments is the ability of the suturing needle to pull the suturing thread entirely through the tissue segments being closed, following each stitch. When using the suturing device of the presently disclosed embodiments, no ancillary instruments or tools such as needle holders, pick-up forceps or the like are needed to complete the stitch. A forceps can be used to tighten the knots.

According to aspects illustrated herein, there is provided a suturing device that includes a suturing needle that is protected by a housing, the suturing needle is not exposed to or handled directly by the user, thereby preventing inadvertent needle sticks. The configuration of the suturing device of the presently disclosed embodiments also protects against inadvertent penetration of internal organs or vessels by the needle, since the housing acts as a shield between the organs and the needle.

The suturing device of the presently disclosed embodiments is useful for suturing tissue internal to a body. An embodiment of the device includes an elongated barrel having a proximal end, a distal end, and a longitudinal axis therebetween; a suture head assembly extending from the distal end of the elongated barrel; a suturing needle having a pointed end and a blunt end, the suturing needle capable of rotating about an axis approximately perpendicular to a longitudinal axis of the elongated barrel, wherein the pointed end of the suturing needle is positioned within the suture head assembly prior to and after rotation of the suturing needle; and an actuator extending from the proximal end of the elongated barrel to actuate a drive mechanism having a needle driver for engaging and rotating the suturing needle.

According to aspects illustrated herein, there is provided a method for suturing tissue during minimally invasive surgery that includes: (a) engaging a cartridge to a suture head assembly at a distal end of a suturing device, the cartridge having a protective housing and a suturing needle with a pointed end and a blunt end; (b) introducing the distal end of the suturing device into a body cavity; (c) positioning an opening in the cartridge to span a plurality of separated tissue segments or a single tissue segment; (d) activating an actuator coupled to a drive mechanism that engages the suturing needle to cause rotational movement of the suturing needle about an axis approximately perpendicular to a longitudinal axis of the suturing device and advance the suturing needle through the plurality of separated tissue segments or the single tissue segment; (e) pulling a suturing material attached to the suturing needle through the plurality of separated tissue segments or the single tissue segment forming a stitch; and repeating steps (c) through (e) to cause a plurality of stitches to be placed through the separated tissue segments or the single tissue segment.

According to aspects illustrated herein, there is provided a method for suturing tissue during minimally invasive surgery that includes: (a) engaging a suturing needle with a pointed end and a blunt end to a suture head assembly at a distal end of a suturing device, the suture head assembly includes a curved track, whereby the suturing needle follows a curved path along the track during rotation of the suturing needle, and a latch that provides a protective housing for the suturing needle; (b) introducing the distal end of the suturing device into a body cavity; (c) positioning an opening in the needle holder assembly to span a plurality of separated tissue segments or a single tissue segment; (d) activating an actuator coupled to a drive mechanism that engages the suturing needle to cause rotational movement of the suturing needle about an axis approximately perpendicular to a longitudinal axis of the suturing device and advance the suturing needle through the plurality of separated tissue segments or the single tissue segment; (e) pulling a suturing material attached to the suturing needle through the plurality of separated tissue segments or a single tissue segment forming a stitch; and repeating steps (c) through (e) to cause a plurality of stitches to be placed through the separated tissue segments or a single tissue segment.

According to aspects illustrated herein, there is provided a method for suturing tissue during minimally invasive surgery that includes inserting a distal end of a suturing device having a suturing needle with a pointed end into a body; positioning the suturing needle to span a plurality of separated tissue segments; activating an actuator a first time causing the pointed end of the suturing needle to extend beyond a protective housing of a cartridge to engage the plurality of separated tissue segments; and activating the actuator a second time to cause the suturing needle to complete a revolution and pull a suture extending from the suturing needle through the plurality of separated tissue segments to form a stitch.

In addition to the advantages discussed above, the suturing device of the presently disclosed embodiments is relatively simple and cost efficient to manufacture. Therefore, the suturing device should find widespread suturing applications that include single stitches or continuous stitches, e.g. spiral, mattress, purse string, etc., that are required to close tissue incisions, attach grafts, or the like.

These and other advantages of the presently disclosed embodiments are illustrated through the embodiments described hereinafter. The presently disclosed embodiments accordingly comprise the features of construction, combination of elements and arrangement of parts that will be exemplified in the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The presently disclosed embodiments will be further explained with reference to the attached drawings, wherein like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the presently disclosed embodiments.

FIG. 1 is a perspective view of a suturing device of the presently disclosed embodiments.

FIGS. 2A and 2B are views of the suture head assembly of the suturing device ofFIG. 1.FIG. 2A is a perspective assembly view of the suture head.FIG. 2B is a cutaway perspective view of the suture head.

FIGS. 3A and 3B are segmented assembly views of the suture head assembly ofFIG. 2.

FIGS. 4A and 4B are cutaway segmental views of the suture head assembly showing interaction points of a suturing needle with a portion of the drive mechanism.FIG. 4A shows the position of the suturing needle and drive mechanism in a “home” position prior to use or after a complete full cycle.FIG. 4B shows the position of the suturing needle and drive mechanism after one full actuation of the handle, where the suturing needle is in a “rotation” position.

FIG. 5, includingFIGS. 5A and 5B are expanded views of the working end of the suture head assembly with a suturing needle in the home position.FIG. 5A shows the relationship between the pawl and anti-rotate spring when the suturing needle is in the home position.FIG. 5B shows a close-up view of the anti-rotate spring.

FIGS. 6A and 6B are expanded views of the working end of the suture head assembly during use of the device.FIG. 6A shows the position of the suturing needle and the pawl immediately after the user squeezes the handle. The user then releases the handle and the pawl returns to the start position (FIG. 6B) while the suturing needle remains in the rotation position.

FIG. 7, includingFIGS. 7A and 7B are expanded views of the pawl in contact with the C-brace while driving the suturing needle.FIG. 7A shows a close-up view of the pawl spring loaded with a spring.FIG. 7B shows a close-up view of the pawl, showing the heel and tip.

FIGS. 8 and 9 are side elevational views of a much larger scale of the internal portions of the drive mechanism located within the handle and elongated barrel.FIG. 8 shows the drive mechanism when the handle is in an open position andFIG. 9 shows the drive mechanism when the handle is in a closed position.

FIGS. 10-13 are top and bottom views of the suture head assembly, including cables that provide the connection between the drive mechanism located in the suture head assembly and the elongated barrel when the handle is in the open and closed positions.FIG. 10 shows a top view when the handle is in the open position.FIG. 11 shows a bottom view when the handle is in the open position.FIG. 12 shows a top view when the handle is in the closed position.FIG. 13 shows a bottom view when the handle is in the closed position.

FIG. 14 is a close-up view of the cartridge holder with a tab that locks into a mating groove on the cartridge holder assembly.

FIG. 15 is a view depicting the suturing needle positioned in the track of the cartridge.

FIG. 16 is a view showing the relation between the cartridge holder assembly, cartridge, latch and C-brace.

FIGS. 17A, 17B and 17C show the suture head assembly.FIG. 17A shows a side view of the suture head assembly.FIG. 17B is a close-up side view showing the relationship between the lever and latch during attachment and ejection of the needle and cartridge from the cartridge holder assembly.FIG. 17C shows a top view of the suture head assembly.

FIG. 18 is an expanded view of a curved suturing needle with notches depicted on the surface of the needle.

FIGS. 19A and 19B depict two exemplary embodiments of the curved suturing needle.

FIGS. 20-23 show different views of the suture head assembly attached to the elongated barrel via a rotation rod. The primary fixation point of the suture head assembly to the elongated barrel is depicted as being at the axis of lateral rotation.FIG. 20 shows a side view of the suture head assembly.FIG. 21 shows a bottom view of the suture head assembly.FIG. 22 shows a bottom view of the suture head assembly articulated to the left.FIG. 23 shows a bottom view of the suture head assembly articulated to the right.

FIGS. 24 and 25 are perspective views of a suturing device.FIG. 24 shows a perspective view of the suturing device with the handles in the open position.FIG. 25 shows a perspective view of the suturing device with the handles in the closed position.

FIG. 26 is a segmented assembly view of the suture head assembly ofFIGS. 24 and 25.

FIGS. 27A and 27B are cutaway segmental views of the suture head assembly ofFIGS. 24 and 25 showing interaction points of a suturing needle with a portion of the drive mechanism.FIG. 27A shows the position of the suturing needle and drive mechanism in a “home” position prior to use or after a complete full cycle.FIG. 27B shows another view of the suturing needle and drive mechanism.

FIG. 28 is a close-up view of the needle holder assembly for the suture head assembly ofFIGS. 24 and 25.

FIG. 29 is a close-up view of the distal end of the suture head assembly ofFIGS. 24 and 25.

FIGS. 30 and 31 show the suture head assembly ofFIGS. 24 and 25.FIG. 30 shows the suture head assembly with the latch in the open position.FIG. 31 shows the suture head assembly with the latch in the closed or locked position.

FIG. 32 is a view of a curved suturing needle with notches on the face of the suturing needle to be used with the suturing device ofFIGS. 24 and 25.

FIG. 33 shows a view of the pawl in contact with the suturing needle for the suturing device ofFIGS. 24 and 25.

FIGS. 34 and 35 show a close-up view of the suture head assembly ofFIGS. 24 and 25 and the associated pulleys that move the drive mechanism.FIG. 34 shows a top view of the suture head assembly.FIG. 35 shows a side view of the suture head assembly.

FIGS. 36 and 37 are top views of the suture head assembly and cables that connect the drive mechanism located in the suture head assembly and the elongated barrel when the handle is in the open position for the suture device ofFIGS. 24 and 25.FIG. 36 shows a top view of the front pulley and cable when the handle is in the open position.FIG. 37 shows a top view of the return pulley and cable when the handle is in the open position.

FIG. 38 shows a side elevational view of the suturing device ofFIGS. 24 and 25 showing parts of the drive mechanism.

FIG. 39A shows a top perspective view of a second embodiment of the suture head assembly made in accordance with the teachings of the invention, in which a resilient elongated member moves proximally and distally to actuate movement of the suturing needle about a circular path.FIG. 39B depicts the suturing head ofFIG. 39A incorporated into a suturing device having a flexible steerable proximal segment.

FIG. 40 shows a sectional view of the drive track of the second embodiment of the suture head assembly, depicting the course of the drive tendon, the drive pawl, and the anti-rotate spring in relation to the suturing needle.

FIG. 41 is a close-up view of the distal end of the drive tendon with attached pawl.

FIG. 42A is an isolated view of the tendon and pawl engaging a notch in the suturing needle

FIG. 42B is an isolated view of an exemplary suturing needle that may be used with the second suturing head embodiment, showing a leading notch and a trailing notch on the side of the needle, and an anti-rotate notch on the outer circumference of the needle.

FIG. 43 is a sectional view of the inside structure of the drive track component of the second embodiment of the suture head assembly, without the tendon, pawl, anti-rotate spring and needle present to highlight the engagement and disengagement tracks, including a flat spring in the proximal chamber used to press the pawl against the drive notch of the needle.

FIG. 44 is a perspective view of a portion of the inside structure of the needle track component of the second embodiment of the suture head assembly, showing one of the pawl body guides, and the aperture through which the anti-rotation spring engages the outer circumference of the needle.

FIG. 45 is a top perspective view of the second embodiment of the suture head assembly, showing the placement of the thrust collar over the lateral side of the needle track, enclosing the needle within it.

FIG. 46A is a sectional view through the upper portion of the second embodiment of the suture head assembly, revealing the cross-section of the pawl as it engages the trailing notch of the needle, and showing the distal ends of both pawl body guides, separating the engagement track from the disengagement track. The relationship of the thrust collar to the needle and needle track is also apparent.

FIG. 46B is a view of the thrust collar in isolation.

FIG. 47 is a sectional view of the second embodiment of the suture head assembly showing the pawl body positioned against the flat spring, which urges the pawl tip against the side of the needle. In this view, the needle is partially spanning the aperture of the suture head assembly, and the anti-rotate spring is visible as it contacts the outer circumference of the needle.

FIG. 48 is an isolated view of the anti-rotate spring.

FIG. 49 is an isolated view of the flat spring, which presses against the pawl body to urge the pawl tip against the side of the needle.

FIG. 50A is a sectional view of the second embodiment of the suture head assembly in which the pawl is at the proximal end of the engagement drive track, immediately proximal to the trailing notch of the needle.

FIG. 50B is a view through section B-B ofFIG. 50A showing the pawl tip pressed against the side of the needle above the notch by a compressed flat spring.

FIG. 50C is a top view through section C-C ofFIG. 50A showing how the flat spring is deflected, pressing the pawl against the side of the needle.

FIG. 51A is a sectional view of the second embodiment of the suture head assembly in which the pawl is within the trailing notch of the needle at the proximal end of the engagement drive track.

FIG. 51B is a view through section B-B ofFIG. 51A showing how the flat spring is relaxed against the pawl when the pawl tip is within the notch of the needle.

FIG. 51C is a top view through section C-C ofFIG. 51A showing the flat spring in a non-deflected state with the pawl tip advanced within the notch of the needle, now in position to drive the needle forward.

FIG. 52 is a sectional side view of the second embodiment of the suture head assembly, showing the needle in the ‘home’ position, the anti-rotate spring engaging the needle, and the pawl within the trailing notch, in position to drive the needle through a suturing cycle.

FIG. 53 is a sectional side view of the second embodiment of the suture head assembly, showing the needle at the end of the push stroke of the first suturing cycle, the pawl having pushed the needle through the aperture, and ready to disengage from the trailing notch.

FIG. 54 is a sectional side view of the second embodiment of the suture head assembly, showing the pawl being released from the trailing notch into the distal end of the disengagement track.

FIG. 55 is a sectional side view of the second embodiment of the suture head assembly, showing the pawl being pulled by the tendon to the proximal end of the track in the pull stroke of the first suturing cycle.

FIG. 56 is a sectional side view of the second embodiment of the suture head assembly, showing the pawl approaching the proximal chamber where the proximal ends of the engagement and disengagement tracks merge. The distal end of the tendon has been deflected away from the leading notch of the needle.

FIG. 57 is a sectional side view of the second embodiment of the suture head assembly, showing the pawl being released into the leading notch of the needle by spring force from the distal tendon that had been deflected as shown inFIG. 56.

FIG. 58 is a sectional side view of the second embodiment of the suture head assembly, showing the push stroke of the second suturing cycle, in which the pointed end of the needle is being advanced to the ‘home’ position by the pawl.

FIG. 59 is a sectional side view of the second embodiment of the suture head assembly, showing the push stroke of the second suturing cycle having been completed, the pawl being urged into the distal end of the disengagement track by the spring force of the distal tendon, and the trailing notch in proper alignment with the proximal chamber.

FIG. 60 is a sectional side view of the second embodiment of the suture head assembly, showing the pull stroke of the second suturing cycle, bringing the pawl back to the proximal end of the disengagement track to be positioned to re-initiate the suturing cycle. Backward rotation of the needle is prevented in this stroke by the anti-rotate spring engaging the anti-rotate notch of the needle.

FIGS. 61-71B describe a further embodiment of a device made in accordance with the invention.

FIGS. 72-85 describe still a further embodiment of a device made in accordance with the invention.

While the above-identified drawings set forth presently disclosed embodiments, other embodiments are also contemplated, as noted in the discussion. This disclosure presents illustrative embodiments by way of representation and not limitation. Numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of the presently disclosed embodiments.

DETAILED DESCRIPTION

The suturing device of the presently disclosed embodiments is shown generally at50 inFIG. 1. Referring toFIG. 1, thesuturing device50 can be used to produce a continuous or interrupted stitch or suture so as to enable closure of openings internal to a patient's body. Thesuturing device50 can be utilized to suture any type of anatomical tissue in any type of anatomical cavity; and, accordingly, while thedevice50 is described hereinafter for use with a cannula in endoscopic procedures, such as laparoscopy, thedevice50 can be used in open surgery and with catheters and other small and large diameter tubular or hollow, cylindrical members providing access to small cavities, such as veins and arteries, as well as large cavities, such as the abdomen.

In anembodiment suturing device50 includes an actuator mechanism shown generally at52 which comprises anelongated barrel54 and ahandle60 that extends from the undersides at a proximal end of theelongated barrel54. Asuture head assembly56 is attached to the distal end of theelongated barrel54. In an embodiment, thesuture head assembly56 is removably attached to the distal end of theelongated barrel54. The length of thesuture head assembly56 can range from about 20 mm to about 100 mm. In an embodiment, the length of thesuture head assembly56 is about 50 mm. The length of theelongated barrel54 can range from about 50 mm to about 400 mm. Those skilled in the art will recognize that theelongated barrel54 can be made shorter or longer depending on the intended use of thedevice50. In an embodiment, theelongated barrel54 is about 300 mm. In an embodiment, theelongated barrel54 is about 350 mm. Anarticulation lever66, just distal to the top of thehandle60 is pushed or pulled to cause thesuture head assembly56 to rotate. Moving thearticulation lever66 clockwise, moves thesuture head assembly56 to the right and moving thearticulation lever66 counterclockwise, moves thesuture head assembly56 to the left. Thearticulation lever66 can also be moved to articulate thesuture head assembly56 up and down. Thesuture head assembly56 is locked in place with a lockinglever64 located on an underside of thedevice50, below thearticulation lever66. Thesuture head assembly56 may be articulated, and theelongated barrel54 may be any length appropriate for the intended clinical application of thedevice50. The diameter of thedevice50 can range from about 3 mm to about 20 mm. In an embodiment, the diameter of thedevice50 is about 12 mm. In an embodiment, the diameter of thedevice50 is about 3 mm. Aflush port62 is located on the side of theelongated barrel54 in order to provide a port of entry for cleaning fluids or suction such that thedevice50 can be cleaned prior to or after use.

Thehandle60 is a grip that is squeezed in order to actuate thesuturing device50. Thesuturing device50 is actuated by theactuator mechanism52 coupled to adrive mechanism70. Theactuator mechanism52 of thesuturing device50 may comprise a triggering mechanism that is known in the art, such as for example, the triggering mechanisms disclosed in U.S. Pat. Nos. 6,053,908 and 5,344,061, both of which are hereby incorporated by reference. Alternatively, the actuator mechanism can be either a manually operable button or switch, or a mechanically operable by an automated electrical or a fuel driven device, such as for example, an electrical, electromagnetic or pneumatic motor powered by electrical, electromagnetic, compressed air, compressed gas, hydraulic, vacuum or hydrocarbon fuels. Those skilled in the art will recognize that any actuator mechanism of any type known in the art can be within the spirit and scope of the presently disclosed embodiments.

The suturing needle (e.g.,120,220) used with thesuturing device50 has an engagement or gripping surface at one or more locations along its length. By way of this surface, an engagement mechanism in thesuture head assembly56 can grip the needle to advance it through the target tissue. This gripping surface can take on a number of different forms, including, for example, one or more serrations or teeth raised above or depressed below the generally toroidal surface of the suturing needle, and properly oriented to allow the suturing needle to advance smoothly through tissue. In this case, the engagement mechanism in thesuture head assembly56 can include one or more number of interfitting teeth. The gripping or engagement surface of the suturing needle can also take the form of hatch marks engraved on the surface of the suturing needle, which either may be raised above or depressed slightly below the surface of the suturing needle. In this embodiment, the engagement mechanism in thesuture head assembly56 can comprise a rubberized contact surface, or a collapsible mesh that can surround the body of the needle at the gripping surface to apply a trapping force against the needle.

In a preferred embodiment, the gripping surface may include one or more notches that penetrate the surface of a suturing needle that is generally toroidal in shape, with the notches located on the outer circumference, inner circumference, or on one or both sides of the suturing needle. A corresponding engagement mechanism in thesuture head assembly56 can comprise a pawl, which can take many forms, but which at a minimum must effectively contact the leading or forward wall of a notch on the suturing needle, either to drive the needle in a forward direction, or to prevent the needle from moving in a reverse direction. The following description uses a particular embodiment of the gripping surface for illustrative purposes, and is not intended to limit the scope of the invention illustrated herein.

FIG. 2A is a perspective view of thesuture head assembly56 with acartridge holder assembly90 located at the distal end to which acartridge88 can be attached. In accordance with one embodiment, thesuture head assembly56 may be fabricated as a single piece.FIG. 2B is a perspective assembly view of the suture head assembly of the presently disclosed embodiments showing part of thedrive mechanism70, shown as a gear train/pulleysystem including pulleys72,74,76 and78. Located within theelongated barrel54 are mechanical parts including drive shafts, belts, rods, cables, or hydraulic tubes which run from theelongated barrel54 through thespherical portion58 and then engages with thedrive mechanism70 in thesuture head assembly56. Connected at the proximal end of thesuture head assembly56 there is depicted aspherical portion58 that contains part of thedrive mechanism70 including twoidler pulleys80 andcables84 and86. Thespherical portion58 resides within the distal portion of theelongated barrel54 and rotates in a substantially frictionless fashion. In one embodiment, thedrive mechanism70 includes a gear train/pulley system (“locomotive-type” drive mechanism) and cables and rods that extend from the distal end of thesuture head assembly56 to the proximal end of theelongated barrel54.

Thesuture head assembly56 is that portion of thedevice50 within which the mechanism for driving thecurved needle120 in a complete 360-degree circular arc, as well as thecartridge holder assembly90 for attaching and releasing thecartridge88 are situated. Thesuturing device50 is unique in the fact that the orientation of thesuture head assembly56 is such that when thecartridge88 is attached to thesuture head assembly56 theneedle120 is driven in a curved path about an axis approximately perpendicular to the longitudinal axis of thedevice50. In this way, theneedle120 may be optimally visualized as theneedle120 is driven in a circular arc. Also, as shown inFIG. 2B, theneedle120 andcartridge88 are in a plane parallel to thedrive mechanism70 and fit into the same space in thesuture head assembly56.

The improved visibility offered by the shape and configuration of thesuture head assembly56 enables precise device placement over the incision or other target tissue of interest, and uniform advancement of thesuturing device50 after every stitch to provide a uniform and symmetric suture, thereby minimizing the risk of tearing tissue and bleeding due to a stitch being positioned too close to the edge of the incised tissue. In one embodiment, theentire device50 or parts of thedevice50, such as thesuture head assembly56, theelongated barrel54, thehandle60, and theneedle120 andcartridge88, may be composed of a sterilizable medical grade plastic material, in which case, theentire device50 or parts of thedevice50 may discarded and disposed after a single use. In another embodiment, thedevice50 may be composed of a sterilizable medical grade metallic material such as stainless steel to enable reuse subsequent to sterilization following a prior use. In still another embodiment, thedevice50 is composed of a sterilizable medical grade metallic material such as titanium to enable reuse subsequent to sterilization following a prior use. The use of titanium is ideal for certain procedures including Magnetic Resonance Imaging (MRI) and Computed Tomography (CT) because they are X-Ray radiolucent and do not interfere with MRI and CT scans.

FIGS. 3A and 3B provide detailed segmental views of thesuture head assembly56 showing thecartridge holder assembly90, thedisposable needle cartridge88, acurved suturing needle120, and parts of thedrive mechanism70 including a plurality of pulleys,72,74,76,78 and80 involved in driving theneedle driver98 through a semicircular path. In one embodiment, the needle driver is apawl98. As depicted, ashoulder screw108 is used to keep alatch110 locked in place over thedisposable cartridge88 and thesuturing needle120.Pulleys72,74,76 and78 are engaged with anactuator arm102, which is attached to thepawl98. Thepawl98 interfits with two notches132 (as depicted inFIG. 15) located on theneedle120 at 180 degrees apart from each other which drives thecurved needle120 in a completely circular arc. Thesuture head assembly56 is preferably configured so that the pawl98 (or other needle driver), does not intrude into or obstruct the area within the curve of theneedle120. The entire area within the circular arc of theneedle120 is unobstructed; there is no hub at the center of the circular arc so that thedevice50 can encompass the maximum volume of tissue within the circular arc of thecurved needle120. In this way, theneedle120 may be rotated through a relatively large arc, allowing theneedle120 to obtain a sufficient “bite” into the tissue. Preferably, theneedle120 will have a radius of curvature of about 3 mm to about 40 mm. In an embodiment, thedevice50 sutures within the limit of the diameter of thesuture head assembly56, which is advantageous to suturing through small cannulas during minimally invasive surgery. In an embodiment, the diameter of thecurved needle120 does not exceed the diameter of thesuture head assembly56.

FIGS. 4A and 4B show detailed views of thedrive mechanism70 located in thesuture head assembly56 with respect to driving theneedle120 during use of the device50 (thecartridge housing88 has been removed to show thedrive mechanism70 in detail). Thedrive mechanism70 includes a plurality of pulleys,72,74,76 and78, and the associated axle pins82, involved in driving thepawl98 through a semicircular path. Theactuator arm102 engagespulleys72 and76 and are pinned75 topulleys72 and76. As pulleys76 and78 rotate with the motion of thecables86 and84, respectively, which reside in the elongated barrel54 (not shown),pulley74 acts as an idler pulley, transferring the motion to the mostdistal pulley72.Pulley72 andpulley76 rotate through identical arcs. Theactuator arm102 provides a connection to thepawl98. Thepawl98 is located in the distal end of theactuator arm102. Thepawl98 is attached to theactuator arm102 by an integral shaft andcollar100 that fits loosely into theactuator arm102 allowing smooth movement. As thehandle60 is closed and opened, thepawl98 moves through the same arc as pulleys72 and76. Thepawl98 at the distal end of theactuator arm102 is capable of engaging thenotches132 located along the radially inner edge of theneedle120. Theactuator arm102 is activated by the user upon squeezing of thehandle60, and is capable of sweeping back and forth in an arc spanning about 190 degrees or more.FIG. 4A shows a detailed view of thedrive mechanism70 and thesuturing needle120 either prior to using thedevice50 or after one complete full cycle of thedevice50.FIG. 4B shows a detailed view of thedrive mechanism70 and thesuturing needle120 after one squeeze of thehandle60. As shown, thedrive mechanism70 has moved in a circular arc greater than about 180 degrees, (about 190 degrees), while thesuturing needle120 has moved in a circular arc of about 190 degrees to drive through the tissue or vessel to be sutured.

The outer surface of theactuator arm102 is shaped to accommodate a C-brace (shown as106 inFIG. 7) that causes thepawl98 to engage theneedle120 and thereby remain in contact. The advancing movement of theneedle120 during operation causes thenotches132 along the radially inner edge of theneedle120 to align with thepawl98 in theactuator arm102, thereby causing thepawl98 to engage thenotches132 due to a positive pressure exerted by the C-brace (not shown), and to “lock” into thenotches132. The rotary advancing movement of theneedle120 is therefore controlled to occur sequentially through about 190 degrees each time the needle is actuated.

FIG. 5A shows a close-up view of the distal end of thesuture head assembly56 with thecartridge88 and theneedle120 in view as well as the relationship between thepawl98 and theactuator arm102 with respect to theneedle120. Theneedle120 is enclosed within thecartridge88, so the sharppointed end124 is not exposed. This needle position, as loaded, is referred to as the “home” position (FIG. 5A). In the home position, theneedle120 is fully contained within thecartridge housing88 to eliminate needle-pricks during handling of thecartridge88 or the loaded device. Squeezing the device handle60 fully, two times, operates thedevice50 through one full cycle. As shown inFIG. 6A, the first full actuation of thehandle60 drives theneedle120 through an about 190 degree arc. The pointed end of theneedle124 exits the protective enclosure of thecartridge88, drives through the tissue to be sutured, and re-enters the protection of thecartridge88 of thedevice50. This position, after the first squeeze of thehandle60, is referred to as the “rotation” position. As shown inFIG. 6B, thehandle60 is then released, and theneedle120 remains in the rotation position while thepawl98 and theactuator arm120 return to their start position. Thehandle60 is then squeezed again driving theneedle120 through an about 190 degree arc and returning theneedle120 to the home position.

FIG. 5A shows theneedle120 in the home position, thepawl98 is engaged in thenotch132 near the suture end ofneedle126. Ananti-rotate spring136 is engaged in thenotch134 on the outer surface of theneedle120, not allowing theneedle120 to move backwards in thecartridge88 of thedevice50. A close-up view of theanti-rotate spring136 is shown inFIG. 5B. In an embodiment, theneedle120 comprises at least oneanti-rotate notch134 and is engaged with at least oneanti-rotate spring136. As thepawl98 drives theneedle120 through a first semi circular arc, theanti-rotate spring136 slips out of thenotch134 and slides over the outer surface of theneedle120. As thepawl98 reaches the end of a first drive stroke, theanti-rotate spring136 snaps in behind the rear corner of theneedle120, near the suturing material or thread146 (seeFIG. 6A). As thepawl98 returns to the start position, theanti-rotate spring136 holds theneedle120 in place, preventing theneedle120 from moving with thepawl98 back toward the start position. Thepawl98 returns to the start position and engages thenotch132 in theneedle120 near the pointed end124 (seeFIG. 6B). When thehandle60 is squeezed a second time, theneedle120 is driven back to the home position.

The width of theaperture118 in thecartridge88 is comparable to and corresponds with the width of the gap in theneedle120 so that when theneedle120 is in the home position (as shown inFIG. 5A) theneedle120 does not project materially into theaperture118. Such an alignment causes theneedle120 to reside entirely within thecartridge88, thereby preventing inadvertent contact of the sharppointed end124 with the user's fingers during handling of thedisposable needle cartridge88 for placement on thecartridge holder assembly90 or disposal after use, and while operating thesuturing device50. Such protection of theneedle120 in thesuturing device50 prevents accidental “needle-pricks” from occurring, thereby substantially reducing the risk of infection caused by pathogenic bacteria or viruses that may contaminate theneedle120 during or after use prior to disposal. Theneedle120 may be rotated in acurved track92 of thecartridge88 about the longitudinal axis of thesuturing device50 to advance the pointedneedle end124 so that theneedle120 first spans theaperture118 and then returns to the home position. The suturing material orthread146 is attached to theneedle120, and therefore follows the path of theneedle120. The suturing material orthread146 may then be cut and secured by an appropriate method, such as for example, by tying, or additional stitches may be placed along the entire wound or incision by repeating the aforementioned process. Every stitch, whether a single, interrupted stitch, or one of a series of continuous, running stitches may be placed in like manner. Thesuturing device50, therefore, may be used to insert either a single stitch, or to insert a suture comprising a plurality of continuous stitches as a replacement method for a more tedious and time-consuming manual suturing process. The terminal end of the suturing material orthread146 may contain a knot or button to prevent the suturing material orthread146 from pulling through the sutured tissue during placement of the first stitch. In an embodiment, thecartridge88 comprises thesuturing needle120 attached to the terminal end suturing material orthread146, and an appropriate length of suturing material orthread146 are all packaged in a sterilizable medical packaging material.

FIG. 7A shows a close-up view of thepawl98 which rides in a track formed by the C-brace106 and thesuture head assembly56. Thepawl98 is spring loaded with aspring104. Thespring104 is engaged to the tip of thepawl98bas shown inFIG. 7A. Thespring104 engages thepawl tip98binto thenotch132 in theneedle120 during the driving stroke of thedevice50 when thehandle60 is closed. Thespring104 also allows the tip of thepawl98bto rotate out ofnotch132 of theneedle120 during the return of thepawl98 to the start position when thehandle60 is opened. The heel of thepawl98astays in contact with the C-brace106 during the driving stroke of thedevice50, preventing thepawl98 from over-rotating and locking theneedle120.FIG. 7B shows a close-up view of thepawl98 showing thepawl heel98aand thepawl tip98b.

Referring now toFIGS. 8 and 9 in conjunction withFIG. 1, the user introduces the distal end portion ofsuturing device50 into a body cavity, via a cannula assembly (not shown), and then laterally articulates thesuture head assembly56 using thearticulation lever66 located just distal to the top of thehandle60. Thesuture head assembly56 is then positioned relative to the tissue/vessel to be sutured, and the user locks thesuture head assembly56 in place using the lockinglever64. The user then, through manipulation of suturingdevice50, positions a plurality of separated tissue segments into the opening defined at the distal end portion of thesuture head assembly56 and within the aperture of thecartridge118. The user, using only one hand, may manipulate thedevice50 while actuating thehandle60 to close an incision with a continuous suture whose stitches may be individually tensioned precisely and uniformly along the length of the suture similar to suturing done by hand in the conventional way. The user may employ a single suture which would extend the entire length of the incision or multiple sutures.

Thedevice50 starts with theneedle120 in the home position and thehandle60 fully open (seeFIG. 8). In an embodiment, thehandle60 is made up of a grip which rests in the user's palm and is squeezed in order to actuate thedevice50. To drive theneedle120 through the tissue to be sutured, the user squeezes thehandle60 moving theneedle120 from the home position to the rotation position. Thehandle60 containslinkages144 to both theupper drive rod142 and thelower drive rod140. Squeezing the handle60 (seeFIG. 9) causes the twodrive rods140 and142 to move in opposite directions. Theupper drive rod142, moves forward while thelower drive rod140 moves backward. The drive rods are connected to thesuture head assembly56 withcables84 and86 and idler pulleys80. Theupper rod142 is connected topulley78 withcable84. Thelower rod140 is connected topulley76 withcable86.

FIGS. 10 and 11 in conjunction withFIG. 8, show the connections and positions ofcables84 and86 and the drive pulleys72,74,76 and78 when thehandle60 is in the open position.FIGS. 12 and 13 in conjunction withFIG. 9, show the connections and positions ofcables84 and86 and the drive pulleys72,74,76 and78 when thehandle60 is in the closed position. The force to moveneedle120 from the home position to the rotation position comes from thelower rod140 pulling backward on thedrive cable86. Thelower rod140 extends nearly the full length of theelongated barrel54, connecting to drivecable86, at the proximal end of theelongated barrel54. As shown inFIG. 11,cable86 exits theelongated barrel54 and enters thesuture head assembly56, passing over anidler pulley80 located in thespherical portion58, then wrapping clockwise (as viewed from the bottom) aroundpulley76 and is secured topulley76 located in thesuture head assembly56. The pulling action ofcable86 causespulley76 to rotate through an arc of approximately 190 degrees. Aslower rod140 pulls backward, theupper rod142 moves forward. Theupper rod142 also extends nearly the full length of theelongated barrel54, connecting to drivecable84, at the proximal end of theelongated barrel54. As shown inFIG. 10,cable84 also exits theelongated barrel54 and enterssuture head assembly56, passing over a secondidler pulley80 located in thespherical portion58, then wrapping (clockwise as viewed from the top) aroundpulley78 and is secured topulley78 located in thesuture head assembly56.Pulley78 is directly linked topulley76 through theactuator arm102, andcables84 and86 are wrapped in opposing directions, so that ascable86 unwinds frompulley76,cable84 winds ontopulley78.

Theneedle120 is held in a path of rotation by a combination of three components. Thecartridge88, the C-brace106 and thecartridge holder assembly90 interact to constrain theneedle120 to the path of rotation (seeFIG. 5). Thecartridge88 is a semicircular shaped component that is held into thedevice50 by a plurality ofextensions94 located on each end of the cartridge88 (seeFIGS. 14 and 15). In an embodiment, the plurality ofextensions94 takes the form of tabs. In an embodiment, thecartridge88 is made from a sterilizable medical grade metallic material such as stainless steel. Thecartridge88 provides some of the support structure for keeping theneedle120 in a rotational path and therefore should be constructed from a material with structural integrity. Those skilled in the art will recognize that any high-strength medical grade material may be used to fabricate thecartridge88, such as a high-strength plastic. In an embodiment, the plurality of extensions are tabs extending from thecartridge housing88. The plurality ofextensions94 lock intomating grooves96 located along on the distal edge of thecartridge holder assembly90 that are located diametrically opposite to one another, and are capable of engaging the plurality ofextensions94 correspondingly located in theneedle cartridge housing88 as shown inFIG. 16.

The proximal end ofcartridge88 is held in place by acartridge holder assembly90, as shown inFIG. 17A. Thecartridge holder assembly90 also includes alatch110, alever112, associatedpins114 and116, ashoulder screw108, ananti-rotate spring136 and at least onegroove96 that can engage with the plurality ofextensions94 located on thecartridge88. It is the interaction of all of the elements of thecartridge holder assembly90 that hold and lock thecartridge88 in place. Thelatch110 slides back to release thecartridge88 and forward to lock thecartridge88 in place. Thelatch110 also has a built into ejector feature, as shown inFIG. 17B. Alever112 is located distal and below theneedle120 and thecartridge88. Thelever112 pivots on apin114. Asecond pin116 located above thepivot pin114, engages with a slot in thelatch110. To release theneedle120 and thecartridge88, thelatch110 is pulled back and thelever112 is rotated up and back, causingpin116 to move back with thelatch110 and to rotate aboutpin114 thus pushing theneedle120 and thecartridge88 from thecartridge holder assembly90. Theneedle120 and thecartridge88 are then removed from thedevice50 by a slight proximal motion to disengage the plurality ofextensions94 from theirmating grooves96 in thecartridge holder assembly90.FIG. 17C shows theneedle120 as it is driven through a first semi circular arc (thehandle60 has partially completed a first full squeeze). As thepawl98 drives theneedle120 through a first semi circular arc, theanti-rotate spring136 slips out of thenotch134 and slides over the outer surface of theneedle120.

Loading of theneedle120 and thecartridge88 is accomplished by engaging the plurality ofextensions94 into bothgrooves96 on thecartridge holder assembly90 and then pressing the proximal ends down against the sloped distal surface of thelatch110. Thelatch110 is spring loaded at the proximal end, thus can slide back as theneedle120 and thecartridge88 are pressed into place and then snap closed to the locked position, retaining theneedle120 and thecartridge88. Thelever112 is down and out of the way of the operation of theneedle120 and thecartridge88.

FIG. 18 shows a close-up view of theneedle120. The twonotches132 are located about 180 degrees apart on the inner surface and assist in driving theneedle120. Thepawl98 engages thenotches132 when driving theneedle120 through the circular motion. Athird notch134 is located on the outer surface of theneedle120. Thenotch134 assists in preventing rotation of theneedle120 and provides an anti-rotation feature. In an embodiment (seeFIGS. 19A and 19B), theneedle120 is formed as a circular split ring with agap122, a sharp, pointedend124, and ablunt end126. Theneedle120 further comprises anopening130 to accommodate the leading end of the suturing material orthread146. In one embodiment, theopening130 is the form of an eye though which the leading end of the suturing material orthread146 may be passed through for attachment to theneedle120. In the illustrated needle120 (FIG. 19A), theopening130 is located adjacent to theblunt end126. Theopening130 however, can be positioned anywhere along the arc or theneedle120 between the apex128 and theblunt end126. In another embodiment (FIG. 19B), theneedle120 comprises anopening130 in the form of a cylindrical bore aligned axially with respect to theneedle120, located at the blunt end126 (FIG. 19B). The leading end of the suturing material orthread146 is inserted into theopening130 and restrained by mechanically crimping. To enable theneedle120 to penetrate tissue to a required depth, the arc length of theneedle120 is preferably about 240 degrees to about 300 degrees. Theneedle120 comprises twosymmetric notches132 along the radially inner edge (“inner notches”) that are positioned proximally to the sharp, pointedend124 and theblunt end126 of theneedle120. Thenotches132 are located directly opposite to each other, each having a perpendicular (about 90 degree) segment and an angular segment that makes an angle of about 60 degrees with the perpendicular segment. Theinner notches132 are engaged by theneedle driver98 of thedrive mechanism70 and enable theneedle120 to undergo a rotary movement upon actuation of thedrive mechanism70, thereby causing theneedle120 to penetrate into and advance through tissue. A similartriangular notch134 is located on the radially outer edge (“outer notch”) of theneedle120 proximally to theinner notch132 closer to the sharp, pointedend124. Theouter notch134 engages with theanti-rotate spring136 located on thecartridge holder assembly90, whereby rotation of theneedle120 in a direction opposite to the advancing direction or “needle backing-up” is prevented. The positive engagement of the needleouter notch134 during operation of the suturing device precludesneedle120 from straying out of sequence during the suturing process.

Thesuture head assembly56 of thedevice50 can be laterally articulated to the left of center and also to the right of center. In one embodiment, thesuture head assembly56 can be laterally articulated through an arc of about 22.5 degrees to the left of center and also to the right of center, for a total of about 45 degrees or more. In addition, the suture head assembly can be articulated up and down. In one embodiment, thesuture head assembly56 can be articulated up and down. The ability of thesuture head assembly56 to be articulated to the left and right of center, as well as up and down, permits the user to position thesuture head assembly56 for many different types of suturing applications. Thearticulation lever66, just distal of the top of thehandle60, is pushed or pulled to cause thesuture head assembly56 to rotate. Viewed from above, moving thearticulation lever66 clockwise moves suturehead assembly56 to the right and moving thearticulation lever66 counterclockwise moves suturehead assembly56 to the left. Thesuture head assembly56 is locked in place with the lockinglever64 located on the bottom of thedevice50, below thearticulation lever66. Movement is accomplished using thesolid articulation rod68 to link thearticulation lever66 to thesuture head assembly56. Thearticulation rod68 is pinned to thearticulation lever66 and to one side of the most proximal section of thesuture head assembly56 so that thearticulation rod68 pushes or pulls thesuture head assembly56 through a full range of motion (seeFIGS. 20-23).

FIGS. 20-23 show thearticulation rod68 in theelongated barrel54 and the connection to thesuture head assembly56. Thesuture head assembly56 is shown moving from left articulation, to straight to right articulation (some components are not shown to allow clear viewing of the linkage).FIG. 20 shows a side view of thesuture head assembly56.FIG. 21 shows a bottom view of thesuture head assembly56 with no articulation.FIG. 22 shows a bottom view of thesuture head assembly56 articulated to the left.FIG. 23 shows a bottom view of thesuture head assembly56 articulated to the right.FIGS. 20-23 show a number of items. Thearticulation rod68 runs down the center of theelongated barrel54 and is attached to one side of thespherical portion58. The function of thearticulation rod68 is to push and pull thesuture head assembly56 through an articulation. The twoidler pulleys80, which drivecables84 and86 are located in thespherical portion58. Looking atFIG. 20, the twoidler pulleys80 seem to be one on top of the other. Instead however, they are located in plane with eitherpulley76 andlower rod140 orpulley78 andupper rod142.

In accordance with one embodiment, theentire suturing device50 can be designed as a single unit which may be either reusable or disposed after a single use. If desired, theentire suturing device50 can be designed from a number of units which, each unit may be either reusable or disposed after a single use.

Thesuturing device50 is preferably configured to provide a “pistol like” grip for the user that includes anelongated barrel54 and ahandle60 that extends from the proximal end of theelongated barrel54. Theelongated barrel54 has either a linear or non-linear configuration, including but not limited to, straight, curved and angled configurations. Asuture head assembly56 is removably attached to the distal end of theelongated barrel54. Thesuture head assembly56 contains a portion of thedrive mechanism70 of thedevice50. The working end of thesuture head assembly56 has acartridge holder assembly90 to which adisposable cartridge88 that is capable of accommodating asuturing needle120 may reside.

Thedisposable cartridge88 preferably has a generally cylindrical housing with an opening oraperture118 in the sidewall of the housing at the distal or working end thereof. Anarcuate suturing needle120 having a sharp, pointedend124 is slidably mounted in acircular track92 of thecartridge88. A blunt end of theneedle126 is connected to a suturing material orthread146. The radius of the arc defining thearcuate suturing needle120 is approximately equal to the circumference to thecartridge housing88 at theaperture118 therein. Theneedle120 normally resides in a “home” position in thetrack92 such that the gap in thearcuate suturing needle122 is in alignment with theaperture118 in thecartridge88. The sharp, pointed end of theneedle124 is situated on one side and entirely within the confines of thehousing aperture118; the pointed end of theneedle124 is, therefore, shielded by thecartridge housing88. The blunt end of thesuturing needle126 that is attached to the suturing material orthread146 is located at the opposite side of theaperture118. The sharp, pointed end of theneedle124 is, therefore, wholly contained within thecartridge88 and does not protrude beyond the housing of thecartridge88. Thus, the sharp pointed end of theneedle124 is not exposed to the user.

In accordance with the presently disclosed embodiments, theneedle120 may be releasably engaged by aneedle driver98 that is rotatably mounted within thesuture head assembly56 so that theneedle120 can be rotated from the home position by about 360 degrees about the central vertical axis of thecartridge88. Such a rotary action of theneedle120 causes thesharp point124 to advance across thecartridge housing88 so as to span theaperture118. Thus, when thedevice50 is positioned such that the incised tissue segments to be sutured are situated at thehousing aperture118, theneedle120 penetrates the tissue segments and spans the incision between them. A continued rotary movement of theneedle120 causes theneedle120 to return to the home position, and thereby causes the suturing material orthread146 attached to theneedle120 to be pulled into and through the tissue in an inward direction on one side of the tissue incision, and upwards and out through the tissue on the opposite side of the incision. Thus, the suture material orthread146 follows the curved path of theneedle120 to bind the tissues together with a stitch of material orthread146 across the incision in a manner similar to manual suturing, wherein theneedle120 is “pushed” from theblunt end126 and then “pulled” from thepointed end124 by thepawl98. Preferably, an anchoring mechanism is provided at the trailing terminal end of the suturing material orthread146 to prevent the material146 from being pulled completely through and out of the tissue segments. For example, the anchoring mechanism can be a pre-tied or a welded loop, a knot wherein the suture material orthread146 is simply tied, or a double-stranded, looped suture is that attached to thesuturing needle120. The rotary movement of theneedle120 within theneedle cartridge88 is accomplished by apawl98 that may be operated by the user by holding thesuturing device50 with one hand in a pistol-like grip around thehandle60, and using at least one finger of that hand to activate.

Thesuturing device50 of the presently disclosed embodiments can be used for a laparoscopic procedure, including but not limited to laparoscopic colostomy, colectomy, adrenalectomy, splenectomy, repair of paraesophageal hernia, inguinal hernia repair, ventral hernia repair, Nissen fundoplication, liver lobectomy, gastrectomy, small bowel resection, treatment of small bowel obstruction, distal pancreatectomy, nephrectomy and gastric bypass. Those skilled in the art will recognize that the presently disclosed embodiments can be used in other laparoscopic procedures.

In using thedevice50 of the presently disclosed embodiments, the abdomen is insufflated with gas to create a working space for the user. Any gas known to those skilled in the art including, but not limited to, nitrogen or carbon dioxide, can be used. Access portals are established using trocars in locations to suit the particular surgical procedure. A variety of surgical instruments may then be inserted into the body through these access ports/cannulas. The user then introduces the distal end portion ofsuturing device50 into a cannula, and then laterally articulates thesuture head assembly56 using thearticulation lever66 located just distal to the top of thehandle60. Thesuture head assembly56 is then positioned relative to the tissue/vessel to be sutured together, and the user locks thesuture head assembly56 in place using the lockinglever64. The user then, through manipulation of suturingdevice50, positions a plurality of separated tissue segments into the opening defined at the distal end portion of thesuture head assembly56 and within theaperture118 of thecartridge88. The user, using only one hand, may manipulate thedevice50 while actuating thehandle60 to close an incision with a continuous suture whose stitches may be individually tensioned precisely and uniformly along the length of the suture similar to suturing done by hand in the conventional way. The user may employ a single suture which would extend the entire length of the incision or multiple sutures. Thus, by placement of thedevice50 with theneedle cartridge aperture118 spanning the incised tissue segments and actuating thehandle60, thesuturing device50 enables the user to lay down a running stitch or interrupted stitch to close the tissue incision in a time efficient manner. Those skilled in the art will recognize that any conventional procedure for conducting laparoscopic surgery can be used with thedevice50.

Theneedle cartridge88 is disposably mounted on acartridge holder assembly90 at the distal end of thesuture head assembly56. The minimalized structural design of thesuture head assembly56 enables the user to have a clear, unobstructed view of thesuturing needle120 during advancement through the tissue segments during the course of a suturing operation, thereby enabling precise placement of thesuturing device50 to provide uniform sutures and precluding the risk of tearing tissue by placement too close to the edge of the incision. Thesuturing device50 is then advanced a short distance along the incision and the aforementioned operation is repeated to produce another stitch comprising the suturing material orthread146.

The user may continue to manipulate thesuturing device50, alternately advancing and actuating rotation of theneedle120 about an axis that is generally parallel to the direction of advancement to create a continuous suture which may extend through the entire length of the incision or a series of interrupted stitches. After each individual stitch is laid down, the stitch is tightened by exerting a pull on the suturing material orthread146 so that the resultant suture is tensioned uniformly along the length of the incised tissue segments. Therefore, a tight closure of the segments is accomplished and bleeding and tearing of tissue are minimized. Once the appropriate amount of suture material orthread146 has been placed, the user can use a needle grasper to tighten and knot the formed stitches.

The presently disclosed embodiments provide a method for suturing tissue during minimally invasive surgery including engaging acartridge88 to asuture head assembly56 at a distal end of asuturing device50, thecartridge88 having a protective housing and asuturing needle120 with apointed end124 and ablunt end126; introducing the distal end of thesuturing device50 into a body cavity; positioning anopening118 in thecartridge88 to span a plurality of separated tissue segments; activating anactuator52 coupled to adrive mechanism70 that engages thesuturing needle120 to cause rotational movement of thesuturing needle120 about an axis approximately perpendicular to a longitudinal axis of thesuturing device50 and advance thesuturing needle120 through the plurality of separated tissue segments; and pulling asuturing material146 attached to thesuturing needle120 through the plurality of separated tissue segments forming a stitch.

The presently disclosed embodiments provide a method for suturing tissue during minimally invasive surgery including (a) engaging acartridge88 to asuture head assembly56 at a distal end of asuturing device50, thecartridge88 having a protective housing and asuturing needle120 with apointed end124 and ablunt end126; (b) introducing the distal end of thesuturing device50 into a body cavity; (c) positioning anopening118 in thecartridge88 to span a plurality of separated tissue segments; (d) activating anactuator52 coupled to adrive mechanism70 that engages thesuturing needle120 to cause rotational movement of thesuturing needle120 about an axis approximately perpendicular to a longitudinal axis of thesuturing device50 and advance thesuturing needle120 through the plurality of separated tissue segments; (e) pulling asuturing material146 attached to thesuturing needle120 through the plurality of separated tissue segments forming a stitch and repeating steps (c) through (e) to cause a plurality of stitches to be placed through the separated tissue segments.

The presently disclosed embodiments provide a method for suturing tissue during minimally invasive surgery including inserting a distal end of asuturing device50 having a suturingneedle120 with apointed end124 into a body; positioning thesuturing needle120 to span a plurality of separated tissue segments; activating an actuator52 a first time causing thepointed end124 of thesuturing needle120 to extend beyond a protective housing of acartridge88 to engage the plurality of separated tissue segments; activating the actuator52 a second time to cause thesuturing needle120 to complete a revolution and pull asuture146 extending from thesuturing needle120 through the plurality of separated tissue segments to form a stitch.

Thesuturing device50 may be configured in different ways with respect to length and angle of thesuture head assembly56. The size of theneedle120, theneedle cartridge88, thecartridge aperture118 and the aperture position may also be varied for use in open surgery to perform procedures such as closing of the fascia, skin closure, soft tissue attachment, anastomosis, fixation of mesh, grafts and other artificial materials.

FIGS. 24 and 25 show an alternative embodiment of a suturing device shown generally at150. Referring toFIGS. 24 and 25, thesuturing device150 can be used to produce a continuous or interrupted stitch or suture so as to enable closure of openings internal to a patient's body. Thesuturing device150 can be utilized to suture any type of anatomical tissue in any type of anatomical cavity; and, accordingly, while thedevice150 is described hereinafter for use with a cannula in endoscopic procedures, such as laparoscopy, thedevice150 can be used in open surgery and with catheters and other small and large diameter tubular or hollow, cylindrical members providing access to small cavities, such as veins and arteries, as well as large cavities, such as the abdomen.

In an embodiment, thesuturing device150 includes an actuator mechanism shown generally at152 which comprises anelongated barrel154 and ahandle160 that extends from the undersides at a proximal end of theelongated barrel154. Located within theelongated barrel154 are mechanical parts including cables which run from theelongated barrel154 through aspherical portion158 and then engages with the drive mechanism in asuture head assembly156. Thespherical portion158 resides within the distal portion of theelongated barrel154 and rotates with low friction. In an embodiment, adrive mechanism170 includes a pulley system and cables that extend from the distal end of thesuture head assembly156 to the proximal end of theelongated barrel154.

Thesuture head assembly156 houses the mechanism for driving acurved needle220 in a complete 360 degree circular arc. The orientation of thesuture head assembly156 is such that when theneedle220 is attached to thesuture head assembly156 theneedle220 is driven in a curved path about an axis approximately perpendicular to the longitudinal axis of thedevice150. In this way, theneedle220 may be optimally visualized as theneedle220 is driven in a circular arc. Also, as shown inFIGS. 24 and 25, theneedle220 is in a plane parallel to the drive mechanism and fits into the same space in thesuture head assembly156.

The improved visibility offered by the shape and configuration of thesuture head assembly156 enables precise device placement over the incision, and uniform advancement of thesuturing device150 after every stitch to provide a uniform and symmetric suture, thereby minimizing the risk of tearing tissue and bleeding due to a stitch being positioned too close to the edge of the incised tissue. In one embodiment, theentire device150 or parts of thedevice150, such as thesuture head assembly156, theelongated barrel154, thehandle160, and theneedle220, are composed of a sterilizable medical grade plastic material, in which case, theentire device150 or parts of thedevice150 may discarded and disposed after a single use. In an embodiment, thedevice150 is composed of a sterilizable medical grade metallic material such as stainless steel to enable reuse subsequent to sterilization following a prior use. In another embodiment, thedevice150 is composed of a sterilizable medical grade metallic material such as titanium to enable reuse subsequent to sterilization following a prior use. The use of titanium is beneficial for certain procedures including Magnetic Resonance Imaging (MRI) and Computed Tomography (CT) because they are X-Ray radiolucent and do not interfere with MRI and CT scans.

FIG. 24 shows thehandle160 in an open position.FIG. 25 shows thehandle160 in the closed position. Thesuture head assembly156 is attached to the distal end of theelongated barrel154. In one embodiment, thesuture head assembly156 is removably attached to the distal end of theelongated barrel154. The length of thesuture head assembly156 can range from about 10 mm to about 100 mm. In a particular embodiment, the length of thesuture head assembly156 is about 40 mm. The length of theelongated barrel154 can range from about 50 mm to about 400 mm. Those skilled in the art will recognize that theelongated barrel154 can be made shorter or longer depending on the intended use of thedevice150. In one embodiment, theelongated barrel154 is about 300 mm in length. In another embodiment, theelongated barrel154 is about 350 mm in length. Anarticulation lever166, just distal to the top of thehandle160 is pushed or pulled to cause thesuture head assembly156 to rotate. Moving thearticulation lever166 clockwise moves thesuture head assembly156 to the right and moving thearticulation lever166 counterclockwise moves thesuture head assembly156 to the left. Thearticulation lever166 can also be moved to articulate thesuture head assembly156 up and down, as desired. Thesuture head assembly156 is locked in place with a lockinglever164 located on an underside of thedevice150, below thearticulation lever166. Thesuture head assembly156 may be articulated, and theelongated barrel154 may be any length appropriate for the intended clinical application of thedevice150. The diameter of thedevice150 can range from about 3 mm to about 20 mm. In one embodiment, the diameter of thedevice150 is about 12 mm. In another embodiment, the diameter of thedevice150 is about 3 mm.

Thehandle160 may be a grip that is squeezed in order to actuate thesuturing device150. Thesuturing device150 is actuated by theactuator mechanism152 coupled to adrive mechanism170. Theactuator mechanism152 of thesuturing device150 may comprise a triggering mechanism that is known in the art, such as for example, the triggering mechanisms disclosed in U.S. Pat. No. 6,053,908 and U.S. Pat. No. 5,344,061, both of which are hereby incorporated by reference. Alternatively, theactuator mechanism152 can be either a manually operable button or switch, or mechanically operable by an automated electrical or a fuel driven device, such as for example, an electrical, electromagnetic or pneumatic motor powered by electrical, electromagnetic, compressed air, compressed gas, hydraulic, vacuum or hydrocarbon fuels. Those skilled in the art will recognize that any actuator mechanism of any type known in the art can be within the spirit and scope of the presently disclosed embodiments.

FIG. 26 provides an assembly view of thesuture head assembly156. Thesuture head assembly156 is fabricated from multiple pieces including aholder assembly190, aneedle holder assembly188, alatch210, and parts of thedrive mechanism170 including a plurality of pulleys,172,174 and176 and twoidler pulleys180 involved in driving aneedle driver198 through a semicircular path.Pulleys172 and174 may include a set of four pulleys, or two sets of pulleys, labeled178. In one embodiment, the needle driver is apawl198. Ashoulder screw208 and a plurality ofneedle assembly extensions194 may be used to keep thelatch210 locked in place over theneedle holder assembly188 and thesuturing needle220. Theneedle holder assembly188 includes acurved track192 where theneedle220 rides.Pulleys172,174 and176 are engaged with anactuator arm202, which is attached to thepawl198. Thepawl198 interfits with twonotches232 located on the face of theneedle220 at about 180 degrees apart which drives thecurved needle220 in a circular arc. Thesuture head assembly156 is configured so that thepawl198 or other needle driver known in the art, does not intrude into or obstruct the area within the curve of theneedle220. The area within the circular arc of theneedle220 is unobstructed; there is not a hub at the center of the circular arc so that thedevice150 can encompass the maximum volume of tissue within the circular arc of thecurved needle220. In this way, theneedle220 may be rotated through a relatively large arc, allowing theneedle220 to obtain a sufficient “bite” into the tissue. Preferably, theneedle220 will have a radius of curvature of about 3 mm to about 40 mm. In one embodiment, thedevice150 sutures within the limit of the diameter of thesuture head assembly156, which is advantageous to suturing through small cannulas during minimally invasive surgery. In one embodiment, the diameter of thecurved needle220 does not exceed the diameter of thesuture head assembly156.

FIGS. 27A and 27B show detailed views of thedrive mechanism170 located in thesuture head assembly156 with respect to driving theneedle220 during use of the device150 (theneedle holder assembly188 and theholder assembly190 have been removed to show thedrive mechanism170 in detail). Thedrive mechanism170 includes theactuator arm202 that engagespulleys172,174, and176 and thepawl198 that drives theneedle220 through a curved path. Thepawl198 is located in the distal end of theactuator arm202 and is capable of engaging thenotches232 located along the face of theneedle220. Aflat spring200 keeps thepawl198 engaged into thenotches232 of theneedle220. When theneedle220 is pushed around, thepawl198 will be pushed back up against theflat spring200 and allow theneedle220 to cycle. As thehandle160 is closed and opened, thepawl198 moves through the same arc as the pulleys. Theactuator arm202 is activated by the user upon squeezing of thehandle160, and is capable of sweeping back and forth in an arc spanning about 190 degrees or more.

FIG. 28 shows a close-up view of theneedle holder assembly188 showing thecurved track192 where theneedle220 resides as well as the needleholder assembly extensions194 that help keep thelatch210 in place. Thesuturing needle220 follows a curved path along thetrack192 during rotation of thesuturing needle220. Thecurved track192 for theneedle220 may be machined into theneedle assembly188 and provides a captivecurved track192 so that theneedle220 can be driven around with precision. Thecurved track192 includes an inside slot and a larger slot surrounding the inside slot. The larger outside slot provides clearance for thepawl198, so that thepawl198 can maneuver around without hitting anything, and the smaller inside slot provides clearance for apawl tip199, which goes through the smaller inside slot and then into theneedle220 so that thepawl tip199 can drive theneedle220.

FIG. 29 shows a close-up view of thesuture head assembly156 with theneedle holder assembly188, theholder assembly190, thelatch210 and theneedle220 in view as well as the relationship between thepawl198 and theactuator arm202 with respect to theneedle220. Theneedle220 is enclosed within theneedle holder assembly188, so the sharppointed end224 of theneedle220 is not exposed. Thisneedle220 position, as loaded, is referred to as the “home” position. In the home position, theneedle220 is fully contained within theneedle holder assembly188 to eliminate needle-pricks during handling of thesuture head assembly156. Theneedle assembly extensions194 form a “tongue-in-groove” connection with thelatch210, which keeps the forces from theneedle220 from opening the thin members of thelatch210. Theneedle assembly extensions194 cause an entrapment at a distal end of the suturing device, thus locking thelatch210 in place. Squeezing the device handle160 fully operates thedevice150 through one full cycle. The first full actuation of thehandle160 drives theneedle220 through about a 190-degree arc. Thepointed end224 of theneedle220 exits the protective enclosure of theneedle holder assembly188, drives through the tissue to be sutured, and re-enters the protection of theneedle holder assembly188 of thedevice150. This position, after the first squeeze of thehandle160, is referred to as the “rotation” position. Thehandle160 is then released, and theneedle220 remains in the rotation position while thepawl198 and theactuator arm220 return to their start position. Thehandle160 is then squeezed again driving theneedle220 through about a 190-degree arc returning theneedle220 to the home position. Aflat pawl spring200 keeps thepawl198 engaged into thepawl notches232 on theneedle220. When theneedle220 is pushed around thepawl198 will be pushed back up against theflat pawl spring200 and allow theneedle220 to cycle.

FIGS. 30 and 31 show top views of thesuture head assembly156.Needle holder assembly188 forms a connection with thelatch210. Thelatch210 forms a top cover over the suturingneedle220 which is in thecurved track192 of theneedle holder assembly188.FIG. 30 shows thelatch210 in the open position, which is forneedle220 removal and insertion into theneedle holder assembly188. To insert and/or remove the needle220 a user may turn theneedle220 180 degrees in itscurved track192 from the as-drawn position. A user may grab theneedle220 by hand or with a surgical tool to either install theneedle220 or remove theneedle220. By grabbing and lifting theneedle220 out, theneedle220 is removed. By grabbing theneedle220 the needle can be inserted when thelatch210 in the open position.FIG. 31 shows thelatch210 in the locked position, also known as the forward position.

FIG. 32 shows thesuturing needle220. The twonotches232 are located about 180 degrees apart on the face of theneedle220 and assist in driving theneedle220. Thepawl198 engages thenotches232 when driving theneedle220 through the circular motion. Athird notch234 is located on the outer surface of theneedle220. Thenotch234 provides an anti-rotation feature by preventing rotation of theneedle220. Theneedle220 is formed as a circular split ring with agap222, a sharp, pointedend224, and ablunt end226. Theneedle220 further comprises anopening230 to accommodate the leading end of the suturing material orthread246. In an embodiment, theopening230 is the form of an eye though which the leading end of the suturing material orthread246 may be passed through for attachment to theneedle220. In the illustratedneedle220, theneedle220 comprises anopening230 in the form of a cylindrical bore aligned axially with respect to theneedle220, located at theblunt end226. Theopening230, can be positioned anywhere along the arc or theneedle220 between the apex228 and theblunt end226. The leading end of the suturing material orthread246 is inserted into theopening230 and restrained by mechanically crimping or other connection methods known in the art. To enable theneedle220 to penetrate tissue to a required depth, the arc length of theneedle220 is preferably about 240 degrees to about 300 degrees. Theneedle220 comprises twosymmetric notches232 along the face (“drive notches”). Thenotches232 are located directly opposite to each other. Asimilar notch234 is located on the radially outer edge (“outer notch”) of theneedle220 proximally to theinner notch232 closer to the sharp, pointedend224. Theouter notch234 engages with an anti-rotate spring, whereby rotation of theneedle220 in a direction opposite to the advancing direction or “needle backing-up” is prevented. The positive engagement of the needleouter notch234 during operation of the suturing device precludes theneedle220 from straying out of sequence during the suturing process.

FIG. 33 shows a close-up view of thepawl tip199 engaging thedrive notches232 of theneedle220. Thedrive notches232 are engaged by thepawl tip199 of thedrive mechanism170 and enable theneedle220 to undergo a rotary movement upon actuation of thedrive mechanism170, thereby causing theneedle220 to penetrate into and advance through tissue.

FIGS. 34 and 35 show parts of thedrive mechanism170 including return pulleys172 and174.Pulleys172 and174 are connected to each other usingwires175. As can be seen inFIG. 27A andFIG. 27B,pulleys172 and174 are made up of fourpulleys178 that are connected together by laser welding or other methods known in the art. The fourpulleys178 produce an over-rotation, of about 190 degrees. The over-rotation leads to thewire175 design where there is awire175 on each set ofpulleys178. As shown inFIG. 34 andFIG. 35, there are twowires175 with fourpulleys178, resulting in the fourpulleys178 being in synch with one another, even under load. The fourpulleys178 are rotationally in sync, i.e., onepulley178 will follow theother pulley178, because thewires175 are configured to be pulling against one another. Thewire175 may be attached to thepulleys178 via a hole that thewires175 are soldered into.FIG. 35 shows a side view of thesuture head assembly156 which shows the twowires175 connecting the fourpulleys178 together for synchronized rotation.

FIGS. 36 and 37 in conjunction withFIG. 38, show the connections and positions ofcables184 and186 to the drivepulley176 and to the return pulleys172 and174, respectively, and to the when thehandle160 is in the open position. Thecables184 and186 may be made from stainless steel. Connected at the proximal end of thesuture head assembly156 there is thespherical portion158 that contains part of thedrive mechanism170 including twoidler pulleys180 andcables184 and186.FIG. 36 shows a top view of thesuture head assembly156 with thecable184 running through twoidler pulleys180 and wrapped around drivepulley176.FIG. 37 shows a top view of thesuture head assembly156 with thecable186 running through twoidler pulleys180 and wrapped around returnpulley174. Thecable186 runs fromreturn pulley174 through theelongated barrel154 and to the very proximal end of thehandle160. The force to move theneedle220 from the home position (shown inFIGS. 36 and 37) to a rotation position comes from areturn spring240 that is connected to thecable184, resulting in a pre-load (shown inFIG. 38). When the trigger of thehandle160 is squeezed closed, thehandle160 moves to the closed position and thedrive pulley176 turns counterclockwise, driving theneedle220. At the same time, thecable186 drives thereturn pulley174 counterclockwise and cycles theactuator arm202 to drive theneedle220 forward through the tissue. Theneedle220 is driven through a circular motion, through a cycle, and thecable184 is compressing thereturn spring240 on the other end. When thehandle160 closes more, theactuator arm202 drives the needle. When the trigger of thehandle160 is released, thefront pulley178, which is now fully charged with thereturn spring240, will return theneedle220 to the home position. Thereturn spring240 pullscable184, returning the pulleys to their starting positions, and returning theactuator arm202 to a position to engage the second drive notch ofneedle220. A second compression-release cycle returns theneedle220 to the home position. Relaxing the trigger ofhandle160 takes no power.

FIG. 38 shows a side elevational view of thesuturing device150. Thehandle160 includes a number of internal parts—acable connector182 has a hole and a shoulder. The shoulder rides against the end of thereturn spring240, and the hole provides an opening for thecable184. Thereturn spring240 is compressed and thecable184 is soldered or locked to theconnector182, so that thecable184 provides a preload onto thereturn spring240. Thecable184 runs from theconnector182 through thereturn spring240 overpulley244, through theelongated barrel154, through thespherical portion158, between theidler pulleys180 and fixed to the drivepulley176. Thecable186 is connected at the very proximal end of thehandle160 and lies underpulley245, overpulley242, through theelongated barrel154, through thespherical portion158, between theidler pulleys180 and fixed to thereturn pulley174.

When thehandle160 is translated from the open position to the closed position theneedle220 is driven through the tissue. A user has a tactile feel as theneedle220 moves. If theneedle220 runs across something that is impenetrable, thehandle160 will stop moving and the user could feel this in their hand holding the handle. When thehandle160 is in a closed position, thereturn spring240 takes on a charge, thereturn spring240 has shortened in length. When thehandle160 is released, thereturn spring240 pulls thecable184 and brings theneedle220 back to the home position and also brings thehandle160 back to the open position. Thereturn spring240 provides a load on thecable184. A loop is formed throughout thesuturing device150 that includes thecables184 and186 and thepulleys172,174 and176 such thatcable184 is attached at one end to thereturn spring240, at the other end to the drivepulley176. Thecable186 is attached to thereturn pulley174 and thencable186 attaches to the very proximal end of thehandle160, thus forming a loop. Thereturn spring240 can be set to a desired spring-rate so that thereturn spring240 performs as desired by the user. Thereturn spring240 should have a small amount of preload to make sure that thehandle160 opens all the way, which provides that thedriving mechanism170 would return theneedle220 to the home position.

Thecables184 and186 extend through theelongated barrel154 and connect to thedrive mechanism170 in thesuture head assembly156. The long length of thecables184 and186 provides a small amount of a spring buffer. If thesuturing device150 were to become bound or something locked up at thesuture head assembly156 this would not translate. If the user continued to pull on thehandle160 to close thehandle160, thecables184 and186 would stretch and should not break. The twoidler pulleys180, which drive thecables184 and186 are located in thespherical portion158. As shown inFIG. 34, the twoidler pulleys180 appear to be one on top of the other, but they are located in a plane with eitherpulleys174 and176 or pulley178 (seeFIG. 26).

FIG. 39 shows an alternative embodiment of asuture head assembly356. The actuator arm102 (FIGS. 3A, 4A and 4B) of thesuture head assembly56 is replaced by a tendon or band filament302 (FIG. 39). Thecables84 and86, and driverods140 and142 (FIG. 8) can be replaced by an actuator that can move fore and aft with compression and release of the handle60 (FIG. 8) or160 (FIG. 24). The actuator can be a drive rod (not shown), and can be constructed of a tensile material that permits lateral elastic flexibility but minimal longitudinal compressibility, such as steel or other metal alloys with spring-like qualities, shape memory alloys, such as NITINOL® or a flexible hardened polymer or plastic such as high density polyethylene or polypropylene. The drive rod can be encased within a passageway inside theelongated barrel54, the walls of which can include a sufficiently lubricious material to minimize the friction of the fore and aft movement of the drive rod. For example, the passageway may be made from or include a coating of a fluoropolymer or other lubricious material, such as silicone oil and the like. The drive rod can be connected on its distal end to the tendon orfilament302 by any suitable means (including, for example, the use of a screw, a bolt, adhesive, a weld joint, a hinge joint, or a snap-lock connection).

Thesuture head assembly356 can be attached rigidly to theelongated barrel54. Alternatively, thesuture head assembly356 can be attached moveably to theelongated barrel54 by an articulating joint as shown inFIG. 2A andFIGS. 20-23. For example, the proximal end of the suture head assembly356 (FIG. 39) can be modified to form a partially spherical portion similar to spherical portion58 (FIG. 2A), which can permit superior-inferior motion of thesuture head assembly356 with respect to theelongated barrel54. Anarticulation rod68 can be used as shown inFIGS. 20-23 to push and pull thesuture head assembly356 through an arc within the limits of the articulation. Those skilled in the art will recognize there are many possible means of connecting an embodiment exemplified by thesuture head assembly356 to a handle and actuating mechanism to achieve the push-pull motion of the tendon orfilament302.

As shown inFIG. 39A, in this embodiment thesuture head assembly356 is comprised of twomating components356A and356B. Aneedle track332 is located in theneedle track component356B. A drive track (not shown) is located in thedrive track component356A next to theneedle track332. In this embodiment, thesuturing needle220 exits thesuture head assembly356 from the distal end ofaperture318, and re-enters the device at the proximal end ofaperture318. Therefore, in its ‘home’ position, theblunt end226 ofneedle220, and its attachedsuture material246 are situated more proximally in thesuture head assembly356 than the pointed end224 (not shown).

By way of further example, as depicted inFIG. 39B, device300 equipped with asuture head assembly356 may be provided with a flexibleproximal segment354 and include a steering mechanism for controlling curvature of the shaft. The steering mechanism may achieve steering in any suitable manner, such as steering wires. For example, two, four or any other suitable number ofsteering wires371 may be used to control movement of device300. Steering may be controlled accordingly by way of asteering control mechanism372, which may be made in any way known in the art. Similar to the embodiments ofFIGS. 1-38, anactuator373 is also provided for activating the suturing head. As will be appreciated by those of skill in the art, the embodiments ofFIGS. 1-38 may similarly be modified to include a flexible barrel (54,154), as desired.

As embodied herein, thetendon302 may include an elongated flexible member that can slide fore and aft within a track in thesuture head assembly356. It can have any cross-sectional shape, including for example, round, oval, square, or rectangular. In a preferred embodiment, it is relatively flat, forming a band, which has the advantage of limiting the flexibility of thetendon302 to one lateral dimension (e.g., superior-inferior and not side-to-side). It is preferably constructed of material that is minimally compressible, allowing for the longitudinal transmission of a pushing as well as a pulling force. In one embodiment, the material from which a tendon is constructed has sufficient tensile properties to exert a spring-like force that opposes lateral flexion. Examples of material with such properties can include, for example, shape memory alloys such as NITINOL®, steel or other metal alloys with spring-like qualities, or a flexible hardened polymer or plastic such as high density polyethylene or polypropylene. In other embodiments, spring-like properties on lateral flexion are not required, where, for example, the lateral movement of the tendon is urged by a spring located with thesuture head assembly356 that exerts a force against the external surface of the tendon.

As shown inFIG. 40, thetendon302 is situated in adrive track333 within thedrive track component356A of thesuture head assembly356. Thedrive track333 is substantially straight until it reaches the distal portion of thesuture head assembly356, which at this point is shaped to define anaperture318. At this location thedrive track333 in one embodiment divides into anengagement track334, anddisengagement track335, which each follow a curved path conforming to the contour of thesuturing needle220. As shown inFIG. 41,tendon302 flexes to conform to the shape of the engagement and disengagement tracks334 and335.FIG. 41 shows a perspective view of the distal flexed end oftendon302, to which is attached acylindrical pawl308. Thepawl308 consists of apawl body308A and apawl tip308B. The cylindrical shape of thepawl body308A andpawl tip308B reduce the frictional resistance to movement of the tip oftendon302 within engagement and disengagement tracks334 and335. Other cross-sectional shapes of thepawl assembly308A and308B are also possible, including, for example, an oval, a square a rectangle, or other more complex shapes. Moreover, the pawl body can also be constructed as a roller bearing, further reducing frictional resistance to the fore and aft motion of thetendon302.FIG. 42A shows how thepawl tip308B engages a trailingnotch232B or leadingnotch232A onneedle220 to allow thetendon302 to advance theneedle220 within itstrack332.FIG. 42B shows theneedle220 in isolation, in which thedrive notches232A and232B are located on the side of theneedle220, and theanti-rotate notch234 is located on the outer circumference of theneedle220. Apointed end224 pierces the target tissue during forward rotation of theneedle220, andsuture material246 is attached to theblunt end226 ofneedle220.

In one embodiment,notches232A and232B have a substantially perpendicular leading wall232A1 and232B1 against which thepawl tip308B can engage and move the needle forward in itstrack332; whereas the angled trailing walls232A2 and232B2 allow thepawl tip308B to slide smoothly into position in thenotches232 and233 as it advances within theengagement track334. The leading walls232A1 and232B1 ofnotches232A and232B can also be inclined away from the pointed end of the needle, the angle of inclination being in the range of about 91 degrees to about 160 degrees with respect to the surface of the needle. The trailing walls232A2 and23B2 ofnotches232A and232B can also be inclined away from the pointed end of the needle, the angle of inclination being in the range of about 91 degrees to about 160 degrees with respect to the surface of the needle.

Alternatively, the trailing wall232B2 of trailingnotch232B can also be made substantially perpendicular to the surface of the needle, with a gap between the leading wall232B1 and the trailing wall232B2 large enough to accommodate thepawl tip308B. This embodiment allows the user either to advance theneedle220 by pushing thetendon302 distally, or move the needle backwards by pulling thetendon302 proximally when thepawl tip308B is engaged in the trailingnotch232B. The surgeon can thus ‘back out’ the needle from the tissue being sutured when an obstacle is encountered that prevents complete penetration of theneedle220, or when repositioning of the needle in tissue is desired for other reasons. Under these circumstances, the leading wall233A1 of leadingnotch232A is preferably not angled away from the pointed end in order to avoid a ‘barb-like’ structure that would impede reversal of the needle path in tissue. In addition, the leading wall233A1 can have a chamfered or rounded corner at the junction with the surface ofneedle220 to facilitate backing the needle out of tissue. For the same reasons, theanti-rotate notch234 can have a leading wall that does not angle away from thepointed end224 of theneedle220, and it can have a chamfered or rounded corner at the junction with the surface of theneedle220. The trailing wall232B2 of trailingnotch232B can also be constructed with a chamfered or rounded corner to facilitate forward movement of the needle through tissue.

As shown inFIG. 43, in one embodiment, thetrack333 divides intoengagement track334 anddisengagement track335.Engagement track334 is adjacent to and side-by-side with theneedle track332.Disengagement track335 is adjacent to the outside circumference ofengagement track334. Pawl body guides336A (FIG. 43) and336B (FIG. 44)separate engagement track334 fromdisengagement track335, except for a gap between the pawl body guides336A and336B running the length of thetracks334 and335. (best shown inFIG. 46A) The base ofpawl body guide336A is either formed or attached along the inside wall of thedrive track side356A ofsuture head assembly356. The base ofpawl body guide336B is either formed or attached along the inside wall of theneedle track side356B ofsuture head assembly356. The pawl body guides336A and336B terminate short of the ends of thetracks334 and335, both at their proximal and distal ends, atproximal chamber380 anddistal chamber390. This allowsengagement track334 to be in full communication withdisengagement track335 at both theproximal chamber380 and thedistal chamber390 of the tracks.Tendon302 moves only withinengagement track334, whereas thedistal end302A oftendon302 andpawl308 can move inengagement track334 when drivingneedle220, and move in disengagement track305 when returning toproximal chamber380. At theproximal end308 of the engagement and disengagement tracks334 and335 (i.e. at the proximal chamber380), the spring force caused bytendon302 being flexed in a downward direction causes thepawl308 to move up into the proximal end ofengagement track334. As the tendon moves distally in theengagement track334, it engages the trailingnotch232B or leadingnotch232A ofneedle220, moving theneedle220 forward in itstrack332. When thepawl308 reaches the distal end of thetrack334 at thedistal chamber390, thetendon302 is flexed in an upward direction, and the spring force oftendon302 now exerts a downward force on thepawl308. Thepawl308 drops down into the distal end ofdisengagement track335. The distal end oftendon302 comprises a narrowedsegment302A, allowing this distal segment to travel within thedisengagement track335 astendon302 is pulled proximally, because the narrower dimension of the distal end oftendon302 clears the pawl body guides336A and336B. The more proximal portion oftendon302, at full width, continues to travel inengagement track334, being held in place by the pawl body guides336A and336B.

FIG. 45 shows a top perspective view of thesuture head assembly356. Thedrive track side356A is mated to theneedle track side356B. Theneedle track332 is formed on the outside surface of theneedle track side356B of thesuture head assembly356. In this embodiment, asecond opening357, located at the distal end ofaperture318, is where thepointed end224 ofneedle220 exits the device. Afirst opening358, located at the proximal end ofaperture318, is where thepointed end224 ofneedle220 re-enters thesuture head assembly356 after penetrating the target tissue.FIG. 46A shows a cutaway top perspective view ofsuture head assembly356, in which the roof oftrack333, theproximal chamber380, and thedistal chamber390 have been cut away. Thepawl308 can be seen in cross-section within the proximal end ofengagement track334, adjacent to the cross-section ofneedle220 at trailingnotch232B.Pawl tip308B is engaged in trailingnotch232B ofneedle220. Thepawl308 is held within the track by pawl body guides336 A and336B. Thenarrow segment302A oftendon302 can pass through the gap between pawl body guides336A and336B. Thus while the main portion oftendon302 remains withinengagement track334, thepawl308 andnarrow segment302A oftendon302 can travel either inengagement track334 orengagement track335. Athrust collar360, shown inFIG. 46A (and in isolation inFIG. 46B) snaps over the outside ofneedle220 intosuture head assembly356 to holdneedle220 within itsneedle track332. Alternatively, acartridge88, as shown inFIG. 2A andFIG. 2B, can be used, which can then be attached to acartridge holder assembly90. Acartridge88 can provide operating room personnel with the added safety of avoiding inadvertent puncture from handling an exposedneedle220.

A further enhancement ofsuture head assembly356 is shown inFIG. 47. An anti-rotate spring346 (shown in isolation inFIG. 48), anchored insidesuture head assembly356 can engage a notch on the outer circumference ofneedle220 to prevent backward migration ofneedle220 in itstrack332. As shown inFIG. 44, theanti-rotate spring346 contacts the surface ofneedle220 through anaperture347 lateral to thedisengagement track335 so as not to interfere with movement of the distal end oftendon302 andpawl308. In a preferred embodiment, theanti-rotate notch234 is located on the outer circumference ofneedle220, and sufficiently distally along the needle to cause engagement of theanti-rotate spring346 only when the pointed end ofneedle220 is within the confines ofsuture head assembly356.

An additional feature to coaxpawl308 to engage thenotch232A or232B ofneedle220 is shown inFIG. 47. A flat spring348 (shown in isolation inFIG. 49) is situated withinproximal chamber380 of thedrive track side356A ofsuture head assembly356. Theflat spring348 urges thepawl308 against the side ofneedle220 to engage thepawl tip308B with either the trailingnotch232B or leadingnotch232A. The force exerted byflat spring348 is substantially weaker than the spring force exerted by the downwardly flexedtendon302, allowing the distal end oftendon302 and thepawl308 to move into position at the proximal end ofengagement track334, compressingflat spring348 if necessary. Thus it is possible forpawl308 to engage thenotch232A or232B ofneedle220 even if thepawl308 andnotch232A or232B are not exactly adjacent to one another.FIG. 50A is a cross-sectional view ofsuture head assembly356 showingpawl308 positioned immediately proximal to trailingnotch232B ofneedle220.FIG. 50B is a view ofFIG. 50A through section B-B.Pawl tip308B is pressed against the side ofneedle220 immediately proximal to notch232B by compressedflat spring348.FIG. 50C is a view ofFIG. 50A through section C-C.Flat spring348 deflected bypawl308, maintaining pressure ofpawl tip308B against the side ofneedle220.FIG. 51A is a cross-sectional view ofsuture head assembly356 showingpawl308 positioned within trailingnotch232B ofneedle220.FIG. 51B is a view ofFIG. 51A through section B-B. At this point,pawl tip308B is engaged withnotch232B ofneedle220,spring348 is in a relaxed position, andpawl308 is aligned with the side wall ofengagement track334, allowing it to proceed distally to drive theneedle220 within itsneedle track332.FIG. 51C is a view ofFIG. 51A through section C-C.Flat spring348 is now in a relaxed position, andpawl tip308B is situated withinnotch232B ofneedle220. Once thepawl308 moves distally withinengagement track334, the confines of the track wall itself keep thepawl tip308B engaged withnotches232B or232A.

FIGS. 52-59 are sectional views through the length ofsuture head assembly356 showing the progression of a complete four stroke movement (two push-pull cycles) that causesneedle220 to undergo a 360 degree rotation within itstrack332, penetrating the target tissue in the first stroke of the first cycle. InFIG. 52, thepawl308 is situated at the proximal end ofengagement track334, and is engaged withnotch232B ofneedle220.Anti-rotate spring346 is engaged with theanti-rotate notch234 on the outer circumference ofneedle220, preventing it from moving in a reverse direction. InFIG. 53, thetendon302 has been pushed distally in a first stroke, and has drivenpawl308 to the distal end ofengagement track334. When the ends of pawl guides336A and336B have been cleared, the distal end oftendon302 andpawl308 snap by spring force into the distal end ofdisengagement track335. In this embodiment, movement ofneedle220 bypawl308 in this stroke has caused the pointed end ofneedle220 to exit thesecond opening357 ofsuture head assembly356, traverse theaperture318, penetrated the target tissue, and re-entered thefirst opening358 ofsuture head assembly356. InFIG. 54, thepawl308 and the distal end oftendon302 have dropped into the distal end of thedisengagement track335 by spring force of the upwardly deflectedtendon302. The pull stroke in the first suturing cycle is shown inFIG. 55. Thepawl308 is being pulled bytendon302, which is being retracted proximally by the surgeon via thehandle60 or160. Backward migration of theneedle220 is prevented by the engagement ofanti-rotate spring346 against the hub orblunt end226 ofneedle220. This helps to keep the leadingnotch232A ofneedle220 aligned with theproximal chamber380, where thepawl308 can engage it. InFIG. 56, thepawl308 has reached the end of the pull stroke at the proximal end ofdisengagement track335. At this point thetendon302 is significantly deflected downward, generating a spring force to drivepawl308 upward into the proximal end ofengagement track334, after it has cleared thepawl body guide336A and336B. InFIG. 57, thepawl308 has been driven by spring force into engagement with the leadingnotch232A ofneedle220. The push stroke of the second suturing cycle involves pushing thetendon302 distally, driving thepawl308 and pointed end224 ofneedle220 toward the distal end of needle track332 (visually indistinguishable fromengagement track334 in this view). This is shown inFIG. 58, where thepointed end224 ofneedle220 has advanced half-way throughneedle track332. InFIG. 59, the push stroke of the second suturing cycle has been completed, with the pawl having dropped into the distal end ofdisengagement track335 by spring force from the upward deflection oftendon302. Theneedle220 has returned to its home position. Backward movement of theneedle220 is prevented byanti-rotate spring346 engagement with theanti-rotate notch234 ofneedle220. The trailingnotch232B ofneedle220 is in position to be engaged bypawl308 at the proximal end ofengagement track334. As shown inFIG. 60, the pull stroke of the second suturing cycle is a retraction oftendon302 proximally, pulling thepawl308 proximally withindisengagement track335 and bringing it into position in theproximal chamber380 to re-engage the trailingnotch232B ofneedle220. Backward migration ofneedle220 is prevented byanti-rotation spring346 engaging theanti-rotation notch234 ofneedle220. The suturing cycle is ready to resume if desired at this point.

Those skilled in the art will recognize that the movement of the distal end302B oftendon302 andpawl308 into and out ofnotches232A and232B can be effected by springs situated within thesuture head assembly356 at the beginning ofdisengagement track335 and at the end ofengagement track334. Externally applied spring force, or even the placement of ramps in the engagement and disengagement tracks can cause thepawl308 to be re-directed into the proximal end ofengagement track334, and into the distal end ofdisengagement track335.

It will also be apparent to those skilled in the art that the direction of travel ofneedle220 can be reversed by having the home position for the trailing notch situated in the distal end ofneedle track332. In this case, the pawl and tendon are situated at the distal end ofengagement track334 at the start of the first stroke of the first suturing cycle. The first (pull) stroke of the cycle would cause the pointed end ofneedle220 to exit thefirst opening358, pass through the target tissue, and re-enter the suture head assembly at thesecond opening357. Structured in this way, thedisengagement track335 would be equipped with a spring or ramp to press thepawl308 into thenotch232A or232B at the distal end of the track, and with a spring or ramp to disengage thepawl308 from thenotch232A or232B at the proximal end of the track. Alternatively, thedisengagement track335 can be constructed so that it lies within the inner circumference of theengagement track334 andneedle track332. Under this circumstance, the spring-like property oftendon302 will naturally drive thepawl308 intonotch232A or232B at the distal end, and out ofnotch232A and232B at the proximal end.

In an embodiment, theentire suturing device150 can be designed as a single unit which may be either reusable or disposed after a single use. In one embodiment, theentire suturing device150 can be designed from a number of separable parts where each unit may be either reusable or disposed after a single use.

Thesuturing device150 is configured to provide a “pistol like” grip for the user that includes anelongated barrel154 and ahandle160 that extends from the proximal end of theelongated barrel154. Theelongated barrel154 has either a linear or non-linear configuration, including but not limited to, straight, curved and angled configurations. Asuture head assembly156 is removably attached to the distal end of theelongated barrel154. Thesuture head assembly156 contains a portion of thedrive mechanism170 of thedevice150. The working end of thesuture head assembly156 has aneedle holder assembly188 to which asuturing needle220 may reside. Alatch210 forms a cover over theneedle220.

Anarcuate suturing needle220 having a sharp, pointedend224 is slidably mounted in acircular track192 of theneedle holder assembly188. The blunt end of theneedle226 is connected to the suturing material orthread246. Theneedle220 normally resides in a “home” position in thetrack192 such that the gap in thearcuate suturing needle222 is in alignment with anaperture218 in theneedle holder assembly188. The sharp, pointed end of theneedle224 is situated on one side and entirely within the confines of theneedle holder aperture218; the pointed end of theneedle224 is, therefore, shielded by theneedle holder assembly188. The blunt end of thesuturing needle226 that is attached to the suturing material orthread246 is located at the opposite side of theaperture218. The sharp, pointed end of theneedle224 is, therefore, wholly contained within theneedle holder assembly188 and does not protrude beyond the housing of theneedle holder assembly188. Thus, the sharp pointed end of theneedle224 is not exposed to the user.

In accordance with the presently disclosed embodiments, theneedle220 may be releasably engaged by theneedle driver198 that is rotatably mounted within thesuture head assembly156 so that theneedle220 can be rotated from the home position by about 360 degrees about the central vertical axis of theneedle holder assembly188. Such a rotary action of theneedle220 causes thesharp point224 to advance across theneedle holder assembly188 so as to span theaperture218. Thus, when thedevice150 is positioned such that the incised tissue segments to be sutured are situated at the needleholder assembly aperture218, theneedle220 penetrates the tissue segments and spans the incision between them. A continued rotary movement of theneedle220 causes theneedle220 to return to the home position, and thereby causes the suturing material orthread246 attached to theneedle220 to be pulled into and through the tissue in an inward direction on one side of the tissue incision, and upwards and out through the tissue on the opposite side of the incision. Thus, the suture material orthread246 follows the curved path of theneedle220 to bind the tissues together with a stitch of material orthread246 across the incision in a manner similar to manual suturing, wherein theneedle220 is “pushed” from theblunt end226 and then “pulled” from thepointed end224 by thepawl198. Preferably, an anchoring mechanism is provided at the trailing terminal end of the suturing material orthread246 to prevent the material246 from being pulled completely through and out of the tissue segments. For example, the anchoring mechanism can be a pre-tied or a welded loop, a knot wherein the suture material orthread246 is simply tied, or a double-stranded, looped suture is that attached to thesuturing needle220. The rotary movement of theneedle220 within theneedle holder assembly188 is accomplished by apawl198 that may be operated by the user by holding thesuturing device150 with one hand in a pistol-like grip around thehandle160, and using at least one finger of that hand to activate.

In accordance with further aspects of the invention, for purposes of illustration and not limitation,FIGS. 61-71 depict a further embodiment of asuturing head500 for a suturing instrument.

FIGS. 61-62 illustrate perspective views of this embodiment, both in plain view and showing hidden features, respectively. As illustrated,suturing head500 is comprised of two main housing components,502 and504.Housing component502 defines a portion of aneedle track506 that is complete whencomponents502,504 are assembled. This embodiment is similar to that ofFIG. 39, but with certain differences. Significantly, in contrast to the embodiment ofFIG. 39, this embodiment operates by movingneedle520 throughneedle track506 during a pull stroke offilament530, rather than during a push stroke.Distal end534 offilament530 is attached to anengagement mechanism550 that selectively engages notches formed in theneedle520 in a manner similar to other embodiments described herein. As depicted inFIG. 63, engagement mechanism rides in anarcuate track505 formed inhousing component504 that is generally concentric with theneedle track506.Suturing head500 includes atissue capture gap540, similar to the embodiment ofFIG. 39.

FIG. 65 depicts the engagement mechanism that rides intrack505. As depicted,engagement mechanism550 includes four main components:cap552,sleeve554,piston556 and achamber558 housing a compression spring559 (spring559 is depicted inFIG. 67(B)). In operation,sleeve554 is affixed todistal end534 offilament530,piston556 is received withinsleeve554.Next spring559 is inserted intocap552, which in turn is attached tosleeve554. Reduceddiameter portion556aofpiston556 is urged throughbore554aofsleeve554.Portion556aofpiston556 mates withnotches526,528 inneedle520. The operation ofsuturing head500 through a complete cycle will now be described.

As depicted inFIG. 66,needle520 having a firstpointed end522 and asecond end524 is in the home position prior to a rotation cycle, andengagement mechanism550 is engaged withnotch528 inneedle520. As depicted, needle includes a hollow529 insecond end524 ofneedle520 for receiving a suture (not shown).Filament530 further includes anenlarged portion535 for riding againstneedle track506 to reduce friction and ease operation of the suturing head. As further depicted,tip562 ofpawl560 is biased to engage withantirotate notch527 formed into the outer circumferential surface ofneedle527.

As depicted inFIG. 67(A),filament530 is pulled proximally through the suturing instrument, causingengagement mechanism550 to urge againstnotch528 in needle, resulting inneedle520 being drawn throughtrack506, acrossgap540, and back intotrack506.Tip562 ofpawl560 slides out ofantirotate notch527 ofneedle520 and drags along theneedle520 asneedle520 moves throughneedle track506. As can be seen in side cross-sectional viewFIG. 67(B), end556aofpiston556 is urged againstnotch528 ofneedle520 byspring559.FIG. 68 depictsneedle520 after having been moved through a 180 degree rotation. As can be seen inFIG. 68,second end524 of needle has moved pasttip562 ofpawl560, and tip562 of pawl snaps into theneedle track506 to prevent theneedle520 from reversing direction. At this point,filament530 is once again advanced distally, causingtip556aofpiston556 to urge against the distalinclined surface528aofnotch528.Inclined surface528aacts as a ramp to pushpiston556 intochamber558 against the force ofspring559 untilsurface556arides up out ofnotch528, and over the outer surface ofneedle520 throughtrack505 until it passes overneedle520 and pops back out. Asengagement mechanism550 continues to be guided byarcuate notch505, it encountersfirst end522 ofneedle520. Thepointed end522 ofneedle520 once again acts as a ramp, compressingspring559 assurface556arides up and over theneedle520 untilsurface556areaches notch526. Upon reaching thenotch526, the piston snaps down into the notch. At this position, engagement mechanism is as depicted inFIG. 69.

Next,filament530 is once again pulled proximally through device causing theneedle520 to move through another 180 degree rotation, returning theneedle520 to the home position as depicted inFIGS. 70(A)-70(B). Whileantirotate notch527 can move pasttip562 ofpawl560, whenfilament530 is moved distally once again to pick up the needle atnotch528,needle520 will move backward slightly untilnotch527 engages withpawl tip562. At that point,surface556aofengagement mechanism550 rides upinclined surface526aand travels over the outer lateral surface of theneedle520 until the piston snaps intonotch528, preparing thesuturing head500 for another cycle as depicted inFIGS. 71(A)-71(B).

Suturing head520 can be constructed using any desired techniques and any desired materials as described herein, for example, with reference tosuturing head356. Preferably,suturing head500 is made from a polymeric material to permit manufacture of a low-cost, disposable device.Suturing head500 can be mounted on a flexible shaft as depicted inFIG. 39(B).

In accordance with still further aspects of the invention, for purposes of further illustration and not limitation,FIGS. 72-85 depict further variations of the device generally depicted atFIGS. 1-38.

As depicted inFIG. 72,device600 is provided with ahandle660 that has been found to be particularly user-friendly and comfortable.Device600 also includes asuturing head610, an elongatetubular body640, and aroticulation region650.

Theroticulation region650 is illustrated inFIG. 73. Roticulation section includes ahub652 that is attached totubular body640.Hub652 is rotatably mounted on acylindrical bearing surface658, having a plurality ofelongate detents659 surrounding the bearingsurface658. Adetent ball654 is contained within adetent housing655, wherein aspring656 urgesdetent ball656 into adetent659, preventing the hub from rotating freely, but also permitting hub to be rotated (“roticulated”) about the axis ofdevice600, thereby permitting roticulation of thesuturing head610.

As with the suturing head depicted, for example, inFIGS. 30-31, alatch612 is also provided in the embodiment ofFIG. 72 to cover the suturing needle. Specifically, as depicted inFIGS. 74-76,latch612 is provided, and is preferably biased (e.g., by a spring) to the closed position. Whilelatch612 can be retracted proximally by pushing on thelatch612 itself, during aprocedure latch612 may not be easily accessible. Thus, if thedevice600 should jam, to avoid the difficulty in moving the latch backward to permit the needle to fall out of device, apull wire616 is provided that is attached at its distal end to the latch612 (inside of a bore614), and at its proximal end to arelease trigger618 that pivots about apoint618a. Thus, if it is desired to retract thelatch612 to permit the needle to fall out in the event of a jam, it can be released, thedevice600 can be withdrawn, and the needle can be removed with forceps. Thedevice600 can then be reused with a new needle.

FIGS. 77-83 depict an alternative drive mechanism for thesuturing head610. Specifically, all components of the drive mechanism are fitted to one side of thesuturing head610a, rather than being anchored to both sides of thesuturing head610. This is very advantageous in assembly. Specifically, all drive components (pulleys and the like) are attached toside610aof the suturing head. This prevents any inconvenience in needing to align the pulleys and other drive components with two opposing housing sections, and facilitates assembly generally as this design permits the drive components to be stacked and attached to a single member. As will be noted, the drive components bear some similarity to those depicted inFIGS. 34-35. Adrive cable634 is routed around adrive idler624, and into thedrive pulley620a. Drivepulley620a, in turn, drives anidler pulley621 by way of anactuator arm628 when advancing the suturing needle. A link or strut622 is provided that acts as a stop for rotation ofpulley621 by engaging abearing surface621bingroove621a. A needle engagement mechanism/needle assembly extension628ais provided for driving the suturing needle (not depicted). In addition, areturn cable636 is routed around areturn idler626, and into thereturn pulley620b, which is concentric with thedrive pulley620a.Return pulley620b, in turn, drivesidler pulley621 by way ofactuator arm628 in a direction opposite from thedrive pulley620a, causingengagement mechanism628 a to return to the home position to repeat the half cycle.FIGS. 84-85 depict cross sectional and three dimensional wireframe views of thehandle portion660 ofdevice600, respectively, depicting, for example, actuator handle662 as well as the arrangement of interior passages through which drive and return cables are routed. Thereturn cable636 is preferably spring-loaded so as to cause theneedle engagement mechanism628ato return to its home position.

The suturing devices of the presently disclosed embodiments can be used for laparoscopic procedures, including but not limited to laparoscopic colostomy, colectomy, adrenalectomy, splenectomy, repair of paraesophageal hernia, inguinal hernia repair, ventral hernia repair, Nissen fundoplication, liver lobectomy, gastrectomy, small bowel resection, treatment of small bowel obstruction, distal pancreatectomy, nephrectomy and gastric bypass. Those skilled in the art will recognize that the presently disclosed embodiments can be used in other laparoscopic procedures.

In using thedevice150 of the presently disclosed embodiments, the abdomen is insufflated with gas to create a working space for the user. Any gas known to those skilled in the art including, but not limited to, nitrogen or carbon dioxide, can be used. Access portals are established using trocars in locations to suit the particular surgical procedure. A variety of surgical instruments may then be inserted into the body through these access ports/cannulas. The user then introduces the distal end portion ofsuturing device150 into a cannula, and then laterally articulates thesuture head assembly156 using thearticulation lever166 located just distal to the top of thehandle160. Thesuture head assembly156 is then positioned relative to the tissue/vessel to be sutured together, and the user locks thesuture head assembly156 in place using the lockinglever164. The user then, through manipulation of thesuturing device150, positions a plurality of separated tissue segments into the opening defined at the distal end portion of thesuture head assembly156 and within theaperture218 of theneedle holder assembly188. The user, using only one hand, may manipulate thedevice150 while actuating thehandle160 to close an incision with a continuous suture whose stitches may be individually tensioned precisely and uniformly along the length of the suture similar to suturing done by hand in the conventional way. The user may employ a single suture which would extend the entire length of the incision or multiple sutures. Thus, by placement of thedevice150 with the needleholder assembly aperture218 spanning the incised tissue segments and actuating thehandle160, thesuturing device150 enables the user to lay down a running stitch or interrupted stitch to close the tissue incision in a time efficient manner. Those skilled in the art will recognize that any conventional procedure for conducting laparoscopic surgery can be used with thedevice150.

The minimalized structural design of thesuture head assembly156 enables the user to have a clear, unobstructed view of thesuturing needle220 during advancement through the tissue segments during the course of a suturing operation, thereby enabling precise placement of thesuturing device150 to provide uniform sutures and precluding the risk of tearing tissue by placement too close to the edge of the incision. Thesuturing device150 is then advanced a short distance along the incision and the aforementioned operation is repeated to produce another stitch comprising the suturing material orthread246.

The user may continue to manipulate thesuturing device150, alternately advancing and actuating rotation of theneedle220 about an axis that is generally parallel to the direction of advancement to create a continuous suture which may extend through the entire length of the incision or a series of interrupted stitches. After each individual stitch is laid down, the stitch is tightened by exerting a pull on the suturing material orthread246 so that the resultant suture is tensioned uniformly along the length of the incised tissue segments. Therefore, a tight closure of the segments is accomplished and bleeding and tearing of tissue are minimized. Once the appropriate amount of suture material orthread246 has been placed, the user can use a needle grasper to tighten and knot the formed stitches.

Thesuturing device150 may be configured in different ways with respect to length and angle of thesuture head assembly156. The size of theneedle220, theneedle holder assembly188, theneedle holder aperture218 and the aperture position may also be varied for use in open surgery to perform procedures such as closing of the fascia, skin closure, soft tissue attachment, anastomosis, fixation of mesh, grafts and other artificial materials. Moreover, devices made in accordance with the teachings herein can be used in combination with needle loader devices described, for example, in U.S. patent application Ser. No. 12/175,442, filed Jul. 17, 2008.

All patents, patent applications, and published references cited herein are hereby incorporated by reference in their entirety. It will be appreciated that one or more of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the present disclosure.

Claims (18)

What is claimed is:

1. A suturing device having a proximal end and a distal end comprising:

a) an arced suturing needle having a pointed leading end and a trailing end;

b) a suturing head disposed proximate the distal end of the device, the suturing head being configured to support the arced suturing needle therein, the arced suturing needle having a curved body, the curved body covering an arc greater than about 180°, wherein the arced suturing needle is disposed in and adapted and configured to be advanced along an arcuate path about an axis of rotation substantially perpendicular to a longitudinal axis defined by the suturing device;

c) a reciprocating needle drive configured to advance the needle along a first direction led by the leading end of the needle, wherein reciprocating components of the reciprocating needle drive that are disposed within the suturing head are mounted to the same housing section to facilitate assembly of the suturing head, wherein the reciprocating components of the reciprocating needle drive include at least once reciprocating idler wheel rotatably coupled to the housing section and at least one drive bar pivotally coupled to the reciprocating idler wheel at an outer periphery of the reciprocating idler wheel.

2. The suturing device ofclaim 1, wherein the side of the housing section on which the reciprocating components of the reciprocating needle drive are disposed is located on an interior portion of the suturing head.

3. The suturing device ofclaim 1, wherein the reciprocating components of the reciprocating needle drive that are disposed within the suturing head are mounted to one face of said housing section.

4. The suturing device ofclaim 3, wherein the reciprocating components of the reciprocating needle drive that are mounted to said one face of said housing section are covered by a second housing section to protect said reciprocating components.

5. The suturing device ofclaim 1, wherein said reciprocating components of the reciprocating needle drive that are mounted to said one face of said housing section further include at least one needle driver pivotally connected to said drive bar.

6. The suturing device ofclaim 5, wherein said needle driver includes a drive pawl for releasably engaging a drive notch formed into an engagement surface of the arced suturing needle that faces inwardly toward the axis of rotation of the arced suturing needle.

7. The suturing device ofclaim 6, wherein said drive pawl is urged into contact with said arced suturing needle under spring force.

8. The suturing device ofclaim 6, wherein said drive pawl rides in a carrier track defined at least in part by a C-brace disposed radially inwardly with respect to the arced suturing needle.

9. The suturing device ofclaim 8, wherein the needle is advanced along a needle track that is disposed radially outwardly with respect to the C-brace.

10. The suturing device ofclaim 9, wherein the drive pawl is the only portion of the reciprocating drive in the suturing head that extends into the needle track.

11. The suturing device ofclaim 5, wherein said needle driver includes a spring.

12. The suturing device ofclaim 11, further comprising a removable cartridge disposed in the suturing head, the removable cartridge including a cartridge housing, wherein a needle track is formed into the removable cartridge.

13. The suturing device ofclaim 12, wherein the suturing head includes a coupling for releasably holding the removable cartridge.

14. The suturing device ofclaim 12, wherein the removable cartridge is disposed at a distal end of the suturing head.

15. The suturing device ofclaim 1, wherein the reciprocating needle drive advances the needle through a 360° rotation about the axis of rotation in two 180° drive strokes.

16. The suturing device ofclaim 1, wherein the suturing head is configured to be introduced through a cannula.

17. The suturing device ofclaim 1, wherein the reciprocating needle advancement drive is motorized.

18. The suturing device ofclaim 1, wherein at least a portion of the suturing head is modular and replaceable.

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